Electrical box mounting bracket

• US 6,209,836 B1
• Filed: 04/30/1999
• Issued: 04/03/2001
• Est. Priority Date: 09/27/1996
• Status: Expired due to Term

• Current Assignee: Hubbell, Inc.
• Original Assignee: Hubbell, Inc.
• Inventors: Swanson, Richard D.
• Primary Examiner(s): King, Anita M.
• Application Number:
  US09/302,439
• Time in Patent Office: 704 Days
• Field of Search: 248/300, 248/316.8, 248/342, 248/906, 248/205.1, 248/27.1, 248/343, 248/344, 220/3.3, 220/3.9, 174/54, 174/58
• US Class Current: 248/300
• CPC Class Codes: H02G 1/00 Methods or apparatus specially adapted for installing, maintaining, repairing or dismantling electric cables or lines
• CPC Class Codes: Y10S 248/906 Electrical outlet box support

Abstract

An improved mounting bracket is closed which can be used to selectively support both 4 inch square electric boxes and 4{fraction (11/16)} inch square electrical boxes such that vertical movement of either type of electrical box is limited. The mounting bracket is preferably a one-piece, unitary member stamped from sheet metal. The mounting bracket has a top support rail, a bottom support rail and a pair of mounting ends coupling the support rails together to define a large, elongated central cut-out portion. An electrical box and its associated cover may be mounted between two wall studs by first attaching the mounting bracket of the present invention to the wall studs. The open front end of the box is then placed flush against the rear surface of the bracket such that a top portion of the box contacts the bottom rail of the bracket. Next, the associated cover is placed on the front surface of the bracket opposite and aligned with the box such that a top portion of the cover contacts the top support rail and a bottom portion of the cover contacts the bottom support rail. Finally, the electrical box and the cover are fastened together to complete installation of the electrical box to the bracket. The inner edges of the rails are spaced to engage the mounting screws of a 4 inch square electrical box such that the electrical box cannot significantly move up or down relative to the mounting bracket. The top and bottom support rails are each provided with an abutment for engaging either the outer surface of a 4{fraction (11/16)} inch square electrical box or the faceplate of the 4{fraction (11/16)} inch square electrical box such that the electrical box will not significantly move up or down relative to the mounting bracket when coupled thereto.

Claims

1. A mounting bracket assembly for attachment between first and second adjacent support members, comprising:

a top support rail having a front surface, a rear surface, an inner edge, an outer edge and a top abutment;

a bottom support rail having a front surface, a rear surface, an inner edge, an outer edge and a bottom abutment;

a first mounting end coupled to and extending between first ends of said top and bottom support rails, said first mounting end being adapted to be attached to the first support member;

a second mounting end coupled to and extending between second ends of said top and bottom support rails, said second mounting end being adapted to be attached to the second support member;

said top and bottom support rails being spaced apart by said first and second mounting ends to define an elongated central cut-out portion; and

said inner edges of said top and bottom support rails being spaced apart by a distance which is substantially equal to or slightly greater than an outer distance measured between a pair of mounting holes in mounting ears of a 4 inch square electrical box such that said inner edges of said top and bottom support rails limit relative movement of said 4 inch square electrical box in said central cut-out portion to prevent top and bottom mounting hole portions of a cover of said 4 inch square electrical box from overlapping said top and bottom support rails, respectively, so that top and bottom mounting holes in said top and bottom mounting hole portions respectively, for mounting of a wiring device thereto remain unobstructed by said top and bottom support rails, respectively, and said top and bottom abutments being spaced apart by a distance which is substantially equal to or slightly greater than a 4{fraction (11/16)} inch square electrical box'"'"'s outer dimension such that said top and bottom abutments limit relative movement of said 4{fraction (11/16)} inch square electrical box in said central cut-out portion to prevent top and bottom mounting hole portions of a cover of said 4{fraction (11/16)} inch square electrical box from overlapping said top and bottom support rails, respectively, so that top and bottom mounting holes in said top and bottom mounting hole portions respectively, of said cover of said 4{fraction (11/16)} inch square electrical box for mounting of a wiring device thereto remain unobstructed by said top and bottom support rails, respectively.

2. A mounting bracket assembly according to claim 1, wherein

said top abutment extends rearwardly from said rear surface of said top support rail, and said bottom abutment extends rearwardly from said rear surface of said bottom support rail.

3. A mounting bracket assembly according to claim 2, wherein

said top and bottom abutments are formed as rearwardly extending top and bottom abutment flanges.

4. A mounting bracket assembly according to claim 3, wherein

said top abutment flange is formed adjacent said outer edge of said top support rail, and said bottom abutment flange is formed adjacent said outer edge of said bottom support rail.

5. A mounting bracket assembly according to claim 4, wherein

said top and bottom abutment flanges are substantially continuous along said outer edges of said top and bottom support rails, respectively.

6. A mounting bracket assembly according to claim 1, wherein

said top and bottom abutments are formed on said front surfaces of said top and bottom support rails.

7. A mounting bracket assembly according to claim 6, wherein

said top and bottom support rails are bent to form said top and bottom abutments.

8. A mounting bracket assembly according to claim 7, wherein

said top abutment is formed by a substantially continuous top shoulder, and said bottom abutment is formed by a substantially continuous bottom shoulder.

9. A mounting bracket assembly according to claim 1, wherein

at least one of said top and bottom support rails are free of mounting apertures for accommodating a fastener.

10. A mounting bracket assembly according to claim 1, wherein

said inner edges of said top and bottom support rails are positioned to contact a respective fastening member inserted in a respective one of said mounting holes in said mounting ears of said 4 inch square electrical box to limit relative movement of said 4 inch square electrical box in said central cut-out portion to prevent said top and bottom mounting hole portions of said cover thereof from overlapping said top and bottom support rails, respectively, so that said top and bottom mounting holes remain unobstructed by said top and bottom support rails.

11. A mounting bracket assembly according to claim 10, wherein

said inner edges of said top and bottom support rails contact their respective fastening member at different times depending on a direction of force applied to said 4 inch square electrical box.

12. A mounting bracket assembly according to claim 10, wherein

said inner edges of said top and bottom support rails contact their respective fastening members at substantially the same time.

13. A mounting bracket assembly according to claim 1, wherein

said top and bottom abutments are positioned to contact a respective outer surface of said 4{fraction (11/16)} inch square electrical box to limit relative movement of said 4{fraction (11/16)} inch square electrical box in said central cut-out portion to prevent said top and bottom mounting hole portions of said cover thereof from overlapping said top and bottom support rails, respectively, so that said top and bottom mounting holes remain unobstructed by said top and bottom support rails, respectively.

14. A mounting bracket assembly according to claim 13, wherein

said top and bottom abutments contact their respective outer surfaces of said 4{fraction (11/16)} inch square electrical box at different times depending on a direction of force applied to said 4{fraction (11/16)} inch square electrical box.

15. A mounting bracket assembly according to claim 13, wherein

said top and bottom abutments contact their respective outer surfaces of said 4{fraction (11/16)} inch square electrical box at substantially the same time.

16. An electrical box mounting bracket assembly for attachment between first and second adjacent support members, comprising:

an electrical box having an annular side, a closed rear end and an open front end, said annular side having at least two inwardly extending mounting flanges with a mounting hole in each of said mounting flanges;

a cover having a front surface, a rear surface, at least two mounting slots arranged in alignment with said mounting holes of said electrical box, and top and bottom mounting hole portions defining top and bottom mounting holes therein, respectively, for mounting of a wiring device thereto; and

an electrical box mounting bracket coupled between said open front end of said electrical box and said rear surface of said cover, said electrical box mounting bracket including

a top support rail having a front surface, a rear surface, an inner edge, an outer edge and a top abutment,

a bottom support rail having a front surface, a rear surface, an inner edge, an outer edge and a bottom abutment,

a first mounting end coupled to and extending between first ends of said top and bottom support rails, said first mounting end being adapted to be attached to the first support member, and

a second mounting end coupled to and extending between second ends of said top and bottom support rails, said second mounting end being adapted to be attached to the second support member,

said top and bottom support rails being spaced apart by said first and second mounting ends to define an elongated central cut-out portion,

said inner edges of said top and bottom support rails being spaced apart by a distance which is substantially equal to or slightly greater than the distance between a pair of mounting holes in mounting ears of a 4 inch square electrical box, such that when said electrical box is a said 4 inch square electrical box, said inner edges of said top and bottom support rails limit relative movement of said 4 inch square electrical box in said central cut-out portion to prevent said top and bottom mounting hole portions of said cover thereof from overlapping said top and bottom support rails, respectively, so that said top and bottom mounting holes remain unobstructed by said top and bottom support rails, respectively, and said top and bottom abutments being spaced apart by a distance which is substantially equal to or slightly greater than a 4{fraction (11/16)} inch square electrical box'"'"'s outer dimensions, such that when said electrical box is a said 4{fraction (11/16)} inch square electrical box, said top and bottom abutments limit relative movement of said 4{fraction (11/16)} inch square electrical box in said central cut-out portion to prevent said top and bottom mounting hole portions of said cover thereof from overlapping said top and bottom support rails, respectively, so that said top and bottom mounting holes remain unobstructed by said top and bottom support rails, respectively.

17. A mounting bracket assembly according to claim 16, wherein

said top abutment extends rearwardly from said rear surface of said top support rail, and said bottom abutment extends rearwardly from said rear surface of said bottom support rail.

18. A mounting bracket assembly according to claim 17, wherein

said top and bottom abutments are formed as rearwardly extending top and bottom abutment flanges.

19. A mounting bracket assembly according to claim 18, wherein

said top abutment flange is formed adjacent said outer edge of said top support rail, and said bottom abutment flange is formed adjacent said outer edge of said bottom support rail.

20. A mounting bracket assembly according to claim 19, wherein

said top and bottom abutment flanges are substantially continuous along said outer edges of said top and bottom support rails, respectively.

21. A mounting bracket assembly according to claim 16, wherein

said top and bottom abutments are formed on said front surfaces of said top and bottom support rails.

22. A mounting bracket assembly according to claim 21, wherein

said top and bottom support rails are bent to form said top and bottom abutments.

23. A mounting bracket assembly according to claim 22, wherein

said top abutment is formed by a substantially continuous top shoulder, and said bottom abutment is formed by a substantially continuous bottom shoulder.

24. A mounting bracket assembly according to claim 16, wherein

at least one of said top and bottom support rails are free of mounting apertures for accommodating a fastener.

25. A mounting bracket assembly according to claim 16, further comprising:

fastening members which each engage with a respective one of said mounting slots of said cover and with a respective one of said mounting holes of said electrical box, to secure said cover to said electrical box;

wherein said inner edges of said top and bottom support rails are positioned to contact a respective one of said fastening member inserted in a respective one of said mounting holes in said mounting slots of said 4 inch square electrical box to limit relative movement of said 4 inch square electrical box in said central cut-out portion to prevent said top and bottom mounting hole portions of said cover thereof from overlapping said top and bottom support rails, respectively, so that said top and bottom mounting holes remain unobstructed by said top and bottom support rails.

26. A mounting bracket assembly according to claim 25, wherein

said inner edges of said top and bottom support rails contact their respective fastening member at different times depending on a direction of force applied to said 4 inch square electrical box.

27. A mounting bracket assembly according to claim 25, wherein

said inner edges of said top and bottom support rails contact their respective fastening members at substantially the same time.

28. A mounting bracket assembly according to claim 16, wherein

said top and bottom abutments are spaced from each other to contact a respective outer surface of said 4{fraction (11/16)} inch square electrical box to limit relative movement of said 4{fraction (11/16)} inch square electrical box in said central cut-out portion to prevent said top and bottom mounting hole portions of said cover thereof from overlapping said top and bottom support rails, respectively, so that said top and bottom mounting holes remain unobstructed by said top and bottom support rails, respectively.

29. A mounting bracket assembly according to claim 28, wherein

said top and bottom abutments contact their respective outer surfaces of said 4{fraction (11/16)} inch square electrical box at different times depending on a direction of force applied to said 4{fraction (11/16)} inch square electrical box.

30. A mounting bracket assembly according to claim 28, wherein

said top and bottom abutments contact their respective outer surfaces of said 4{fraction (11/16)} inch square electrical box at substantially the same time.