U.S. patent application number 10/891665 was filed with the patent office on 2005-05-26 for truncated round electrical fixture box.
Invention is credited to Herth, Greg.
Application Number | 20050109907 10/891665 |
Document ID | / |
Family ID | 34573045 |
Filed Date | 2005-05-26 |
United States Patent
Application |
20050109907 |
Kind Code |
A1 |
Herth, Greg |
May 26, 2005 |
Truncated round electrical fixture box
Abstract
A modular interchangeable structural support ceiling fixture
electrical housing box having a truncated cylindrical housing for
mounting one or a plurality of electrical devices, such as ceiling
lighting fixtures or smoke alarm devices. Each housing has at least
one angled mounting bracket for fasteners, such as screws or nails,
for attaching the housing box to a residential ceiling stud so as
to permit interchangeable positioning within the housing. The box
is interchangeable in that it can be used for either a new work box
in new construction or for restoration.
Inventors: |
Herth, Greg; (Oakdale,
NY) |
Correspondence
Address: |
ALFRED M. WALKER
225 OLD COUNTRY ROAD
MELVILLE
NY
11747-2712
US
|
Family ID: |
34573045 |
Appl. No.: |
10/891665 |
Filed: |
July 15, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60523891 |
Nov 20, 2003 |
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Current U.S.
Class: |
248/318 |
Current CPC
Class: |
H02G 3/20 20130101; H02G
3/126 20130101 |
Class at
Publication: |
248/318 |
International
Class: |
E04G 025/00 |
Claims
I claim:
1. A modular structural support electrical work box to support a
light fixture or an alarm device in a ceiling or wall of a
building, said structural support ceiling fixture electrical work
box comprising: a truncated cylindrical housing including a round
wall truncated by a flat sector stud bearing side wall intersecting
said truncated cylindrical wall; said housing of said work box
containing a recess therein for insertion of ceiling fixture or
alarm electrical components, including wires therein; said
structural support ceiling fixture electrical housing box further
having at least one internal angled fastener mounting bracket
therein for inserting a mounting fastener within a ceiling wall
stud to provide a rigid fit of said housing box to said wall stud;
said at least one fastener mounting bracket accommodating at least
one mounting fastener therein; and, said at least one fastener
mounting bracket being located internally within said housing box,
said housing box being attachable to said stud bearing ceiling
wall, said at least one fastener mounting bracket including an
angled sheath for said at least one mounting fastener for mounting
said structural support ceiling fixture electrical housing box
within a ceiling wall of the building.
2. The structural support ceiling fixture electrical work box as in
claim 1 wherein said at least one fastener mounting bracket
comprises a plurality of fastener mounting brackets.
3. The structural support ceiling fixture electrical work box as in
claim 1 further comprising a recess for the placement of electrical
wiring therein.
4. The structural support ceiling fixture electrical work box as in
claim 1 wherein the bottom surface of said housing is substantially
flush with the surface of said ceiling.
5. The structural support ceiling fixture electrical work box as in
claim 1 wherein said at least one fastener mounting bracket
extending at an angle between 30 and 60 degrees perpendicular to
the plane of said ceiling.
6. The structural support ceiling fixture electrical work box as in
claim 5, wherein said angle is about 45 degrees.
Description
RELATED APPLICATIONS
[0001] This application is based upon provisional patent
application No. 60/523,891 filed Nov. 20, 2003 and claims benefit
under 35 USC .sctn. 119(e) thereof.
FIELD OF THE INVENTION
[0002] This invention relates to residential and commercial
electrical wiring, and more particularly to modular structural
support ceiling fixture electrical box for mounting ceiling
lighting fixtures, wall lighting sconces or smoke/carbon monoxide
alarm devices.
BACKGROUND OF THE INVENTION
[0003] Ceiling lighting fixtures are often mounted to a bracket
across a box attached to a stud in the ceiling. These bracket
mounts are less than stable for the ceiling lighting fixture,
making loosening and/or falling of the fixture within the realm of
possibility.
[0004] Existing electrical work boxes are described in U.S. Pat.
No. 4,424,406 of Slater and U.S. Pat. No. 4,436,952 of
Lockwood.
[0005] Lockwood '952 describes a work box with a conventional
accessory screw holding bracket protruding up from the surface of
one of the walls of the work box. The protruding bracket interferes
with the flush placement of the work box within a hole within a
wall corresponding in shape to the exterior of the work box.
[0006] Slater '406 describes a work box in general but is silent
about a mounting means for the work box.
[0007] An improvement in electrical work boxes is shown in
Applicant's U.S. Pat. No. 5,600,093 of Herth and Davis, which
describes an electrical work box for new work and old work, wherein
a novel interior attachment is described for vertically attaching
the electrical work box to a building stud via an angled screw
mount within the electrical work box.
[0008] However, Herth and Davis '093 does not describe a round
ceiling mounted box which can be mounted to a ceiling stud to
firmly suspend a ceiling lighting fixture or smoke/carbon monoxide
alarm device therefrom.
OBJECTS OF THE INVENTION
[0009] It is therefore an object of the present invention to
provide a dual purpose structural support ceiling fixture
electrical work box, which can be adapted for multiple uses in
either new construction or existing building renovations.
[0010] It is another object of the present invention to provide a
structural support ceiling fixture electrical work box with an
internal fastener mounting bracket, for fasteners, such as screws
or nails.
[0011] It is yet another object of the present invention to provide
a work box with a screw mounting bracket, which does not protrude
above the exterior silhouette shape of the work box.
[0012] It is yet an object of the present invention to provide a
structural support for smoke/carbon monoxide devices for
buildings.
[0013] A further object of the present invention is to provide
structural support ceiling fixture electrical work box which is
economical to manufacture, easy to mount and of sturdy
construction.
[0014] Therefore, these objects and related objects are attained in
a structural support ceiling fixture electrical work box having a
structure for holding different ceiling lighting fixtures, wall
sconces or smoke/carbon monoxide alarm devices.
[0015] In a preferred embodiment, the structural support ceiling
fixture electrical work boxes are truncated cylinders formed with
one or more internal fastener mounting brackets in a flat sector
wall, for inserting fasteners, such as nails or screws, within
ceiling and/or wall studs, to provide a rigid flush fit of the
structural support ceiling fixture or alarm device box to the wall
and/or ceiling stud.
SUMMARY OF THE INVENTION
[0016] In accordance with the foregoing objects, and others which
may become apparent, the present invention includes a round
truncated cylindrical structural support ceiling fixture electrical
box housing, for mounting ceiling or wall electrical devices, such
as ceiling lighting fixtures, wall sconces or alarm devices,
wherein the housing box includes a recess therein for accommodating
electrical wires within the recess.
[0017] The round, truncated cylindrical structural support box for
ceiling fixtures, wall sconces or alarm devices, such as smoke,
fire or carbon monoxide detection, contains a round cylindrical
wall interrupted at a sector of arc of the cylinder with a flat
portion. The round, truncated cylindrical structural support box
has no external screw mounting bracket protrusions to interfere
with the fitting of the structural support ceiling fixture box
within pre-cut holes within a ceiling.
[0018] Typically, the structural support ceiling fixture electrical
work box of the present invention includes fastener mounting
bracket portions in the ceiling and/or wall stud bearing flat
truncated portion. The box preferably contains one or more internal
built-in angled fastener mounting bracket channel sheaths for
accommodating fasteners, such as wood screws or nails, to wooden
studs, or self tapping screws for metal studs. The angled mounting
brackets extend at about 30 to 60 degrees, preferably about 45
degrees, so that the nails or screws can be easily mounted is that
the need for external fastener mounting wings.
[0019] The structural support ceiling fixture electrical work box
of the present invention is interchangeable, so that the structural
support ceiling fixture electrical work box can be mounted on
either the left or right side of the ceiling and/or wall stud.
Therefore, the structural support ceiling fixture electrical work
box can be reversed sideways in position.
[0020] The structural support ceiling fixture box includes one or
more inwardly protruding channel wings with holes to accommodate
fasteners for the electrical device, such as a ceiling lighting
fixture or smoke/carbon monoxide alarm device. The open bottom of
the box is flush with the building and/or ceiling wall, to allow
the ceiling lighting fixture or alarm device to be firmly suspended
therefrom.
[0021] The purpose of the cylindrical shape is to accommodate the
wiring of the device in a ceiling hole. The truncated flat wall is
molded integral with the ceiling box, so that the internal fastener
mounting bracket within which the fastener, such as a nail or a
screw, is inserted has a flat support surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The present invention can best be understood in conjunction
with the following drawings, in which:
[0023] FIG. 1 is a top perspective environmental view of the
electrical box of the present invention, shown attached a ceiling
wall stud;
[0024] FIG. 2 is an exploded front elevational view in cross
section of the electrical box of FIG. 1, taken along directional
view lines "2-2" of FIG. 1;
[0025] FIG. 3 is a top plan view of the structural support ceiling
fixture box of the present invention as in FIGS. 1 and 2, taken
along directional view arrow "3" of FIG. 2;
[0026] FIG. 4 is a front elevational view of the electrical box as
in FIG. 3, taken along directional view arrow "4" of FIG. 3;
[0027] FIG. 5 is a bottom view of the box shown in FIGS. 1-4, taken
along directional arrow "5" of FIG. 4;
[0028] FIG. 6 is a bottom view of an alternate embodiment for a
truncated round electrical box having two pairs of opposite fixture
mounting tabs.
[0029] FIG. 7 is a perspective view of an upwardly lit wall sconce
lamp, mounted with the electrical box of the present invention;
[0030] FIG. 8 is a perspective view of a downwardly lit wall
mounted lamp, attached to a stud by the electrical box of the
present invention; and,
[0031] FIGS. 9-11 are diagrammatic front elevational views of the
truncated round electrical box of the present invention, shown
mounted respectively to the right of a building wall stud, above a
connected brace between two adjacent wall studs, and to the left of
a building wall stud.
DETAILED DESCRIPTION OF THE DRAWINGS
[0032] The structural support ceiling fixture electrical housing
box 10 of the present invention includes a truncated cylindrical
housing wall 11 extending continuous with a flat truncated sector
wall 12. One or more interchangeable fastener mounting brackets 28,
30 are mounted within housing box 10 for accommodating holding
fasteners 32, such as screws or nails, for mounting the ceiling
fixture box 10, in particular, flush to, a building ceiling wall
stud 36.
[0033] Work box 10 is interchangeable in that work box 10 can be
used in old construction, which is retrofitted into an existing
wall 36, wherein a generally round cut is made in the sheetrock
ceiling and housing box 10 is attached to wall stud 36, within the
cut, which cut is shaped to conform to the generally round shape of
structural support ceiling fixture electrical housing box 10.
[0034] Because housing box 10 does not have any external protruding
fastener mounting brackets, extending outside of the periphery of
the outside cylindrical walls 11, work box 10 can be easily and
snugly fit in place within the cut made within ceiling wall 36.
[0035] In the alternative, structural support ceiling fixture
electrical housing box 10 may be used in new construction wherein
housing box 10 is attached tightly to stud 36 of a ceiling.
[0036] In referring to FIGS. 1-5, work box 10 includes truncated
flat mounting sector wall face 12 and round interrupted cylindrical
wall 11. Flat mounting sector wall face 12 includes angled mounting
brackets 28, 30 for holding screws within bores within extension
sheath members 14a and 16a within brackets 28 and 30 respectively.
Extension brackets 28, 30 extend from the interior side of
truncated flat sector face 12 of the work box 10, within interior
recess 10a of housing box 10.
[0037] Mounting bracket module 28, and preferably a second fastener
mounting bracket module 30, accommodate one or more mounting
fasteners 32, such as screws or nails therein, wherein one fastener
32 is inserted within an extension sheath member 14a and/or
extension sheath member 16a of respective internal screw mounting
brackets 28 and/or 30 at an angle relative to the planar surface of
truncated flat mounting sector wall 12, for screwing into a
conventional ceiling stud 36.
[0038] A second fastener 32, such as a screw or nail, may be
mounted within further internal screw mounting bracket 30 of
housing box 10.
[0039] An advantageous feature of the truncated cylindrical
structural support ceiling fixture housing box of the present
invention is that the fastener mounting brackets 28, 30 are fully
contained within the confines of the flat truncated cylindrical
structural support ceiling fixture housing box 10, and the flat
truncated wall 12 is flush with the stud 36 of the ceiling bearing
wall, so that no protruding portion interferes with the positioning
of round structural support ceiling fixture housing box 10 within
the building wall.
[0040] As noted, fastener 32, such as screws or nails, may be
mounted within a wood stud 36 and self-tapping screws (not shown)
may be mounted within metal walls (not shown). Fasteners 32 must be
mounted at an angle, generally about 45 degrees, although fasteners
32 may vary in range from 30 degrees to 60 degrees.
[0041] Because housing box 10 is recessed within the surface of the
ceiling, generally sheetrock, it is difficult for physical access
to insert a fastener, such as a hammer or a screwdriver, therefore
the fastener must be inserted at a angle within interior recess 10a
of structural support ceiling fixture electrical work box 10.
[0042] Additionally, there is more structural stability of the
mounting of work box 10 when fastener 32 is inserted at an angle
within stud 34.
[0043] For ease of manufacturing, structural support ceiling
fixture electrical work box 10 is made in a truncated cylindrical
configuration, as shown in the drawing figures, wherein side wall
12 is generally flat.
[0044] Structural support ceiling fixture electrical housing box 10
also has conventional apertures with push-in clamping covers 80,
82, 84 and 86 forming apertures therein, to accommodate
conventional incoming wires into and out of ceiling fixture housing
box 10. These apertures receive electrical wires for attachment to
the ceiling fixture or alarm device (not shown) attached to the
housing box.
[0045] Therefore, the present invention is an improvement over the
prior art because structural support ceiling fixture electrical
work box 10 is interchangeable, whether it functions as an
structural support ceiling fixture electrical work box for new work
or old work. Conventional Madison-type clips may be used for
securing the work box to the sheetrock. However because of the
stability of the present configuration of structural support
ceiling fixture electrical work box 10, auxiliary Madison clips may
not be needed.
[0046] As shown in FIGS. 3 and 5, a pair of opposite fixture plate
mounting brackets 60, 62 support a mounting plate of a lighting
fixture or a smoke/fire/carbon monoxide alarm attached to
electrical box 10.
[0047] However, as shown in FIG. 6, two pairs 60, 62 and 64, 68 of
opposite fixture plate mounting brackets may be provided to mount
lighting fixtures or alarms thereto.
[0048] Housing box 10 is a mirror image reversible, so that it may
be mounted on either side of a ceiling stud.
[0049] Furthermore, various modifications may be made to the
present invention, which will become apparent from the pending
claims, without departing from the spirit and scope of the present
invention, as is noted in appended claims.
* * * * *