U.S. patent application number 11/131325 was filed with the patent office on 2006-11-23 for electrical ceiling box for fixture support.
This patent application is currently assigned to Hubbell Incorporated. Invention is credited to Steven J. Johnson, Krzysztof W. Korcz.
Application Number | 20060260835 11/131325 |
Document ID | / |
Family ID | 37447283 |
Filed Date | 2006-11-23 |
United States Patent
Application |
20060260835 |
Kind Code |
A1 |
Johnson; Steven J. ; et
al. |
November 23, 2006 |
ELECTRICAL CEILING BOX FOR FIXTURE SUPPORT
Abstract
An electrical box has a side wall with at least one mounting
flange that is contained completely within the perimeter of the
side wall. The flange is coupled to the side wall along a common
non-linear edge to resist bending of the flange along the joining
edge with the side wall. In one embodiment, the electrical box has
a substantially circular side wall with at least one recessed
portion. The mounting flange is connected to the upper edge of the
recessed portion and is positioned within a radius of the circular
side wall.
Inventors: |
Johnson; Steven J.; (Galien,
MI) ; Korcz; Krzysztof W.; (Granger, IN) |
Correspondence
Address: |
ROYLANCE, ABRAMS, BERDO & GOODMAN, L.L.P.
1300 19TH STREET, N.W.
SUITE 600
WASHINGTON,
DC
20036
US
|
Assignee: |
Hubbell Incorporated
|
Family ID: |
37447283 |
Appl. No.: |
11/131325 |
Filed: |
May 18, 2005 |
Current U.S.
Class: |
174/58 |
Current CPC
Class: |
H02G 3/20 20130101; H02G
3/125 20130101; Y10S 248/906 20130101 |
Class at
Publication: |
174/058 |
International
Class: |
H01H 13/04 20060101
H01H013/04 |
Claims
1. An electrical ceiling box for supporting an electrical device,
said box comprising: a bottom wall; a substantially circular side
wall having a bottom end coupled to said bottom wall and having a
concave inner surface, a convex outer surface, and at least one
recessed portion, said recessed portion having a continuously
curved concave outer surface connected to said convex outer surface
of said side wall and a continuously curved convex inner surface
connected to said concave inner surface of said side wall; and a
mounting flange integrally formed with said side wall and said
recessed portion and extending outwardly from a top end of said
side wall to overlie said recessed portion.
2. (canceled)
3. The electrical ceiling box of claim 1, wherein said convex outer
surface of said recessed portion has a substantially arcuate shape
and said flange has an inner edge with a substantially arcuate
shape with a length substantially equal to a length of said
recessed portion.
4. The electrical ceiling box of claim 1, wherein said recessed
portion is contained completely within a radius of said side wall
and said mounting flange.
5. The electrical ceiling box of claim 4, wherein said mounting
flange is contained completely within said radius of said side wall
and is coextensive with said recessed portion.
6. A universal electrical ceiling box adapted to support an
electrical device comprising: a bottom portion having a plurality
of mounting holes adapted for receiving fasteners for mounting said
box to a support surface, said bottom portion having an outer edge
defining an outer dimension of said box; a continuous side wall
extending from said outer edge in a direction substantially
perpendicular to said bottom portion defining an internal cavity,
said side wall having an outer surface with a first continuously
curved concave recessed portion extending in an inward direction
with respect to said box; and a first flange extending from an
upper end of said side wall substantially parallel to said bottom
portion and overlying said concave recessed portion in said side
wall, said first flange having a plurality of holes extending
therethrough and adapted for receiving a fastener for coupling said
electrical device to said box, said holes in said first flange
being aligned with said concave recessed portion and being
positioned outwardly with respect to said side wall, said first
flange has an inner arcuate shaped portion integrally formed with
said first concave recessed portion of said side wall and an outer
arcuate shaped portion having a radius of curvature substantially
equal to a radius of curvature of said side wall.
7. The ceiling box of claim 6, wherein said side wall has a first
arcuate shaped section and a second arcuate shaped section with a
first radius of curvature; and said first concave recessed portion
extends between a first end of said first arcuate shaped section
and a second end of said second arcuate shaped section, and where
said first concave recessed portion has a substantially arcuate
shape with a second radius of curvature that is less than said
first radius of curvature.
8. The ceiling box of claim 6, wherein said side wall has a second
concave recessed portion and a second flange extending from the
upper end of said side wall and overlying said second recessed
area.
9. The ceiling box of claim 8, wherein said second concave recessed
portion has an arcuate shape with a radius of curvature less than a
radius of curvature of said side wall.
10. The ceiling box of claim 9, wherein said second flange has an
inner arcuate shaped portion integrally formed with said second
concave recessed portion of said side wall and an outer arcuate
shaped portion having a radius of curvature substantially equal to
the radius of curvature of said first arcuate shaped portion of
said side wall.
11. The ceiling box of claim 6, further comprising a raised portion
formed in said bottom portion and having a substantially planar
surface parallel to said bottom portion and having a height less
than a height of said side wall, said raised portion having a hole
for receiving a screw to connect a ground wire to said box, said
raised portion forming a recess on an outer face of said bottom
portion.
12. The ceiling box of claim 11, wherein said raised portion is
spaced from said side wall.
13. The ceiling box of claim 11, wherein said raised portion is
contiguous with said first concave recessed portion.
14. An electrical ceiling box adapted to support an electrical
device and formed as a one piece integral unit, comprising: a
bottom wall having a peripheral edge and a plurality of mounting
holes extending therethrough for receiving a fastener for coupling
said box to a support surface; a side wall extending in a
substantially perpendicular direction from said peripheral edge of
said bottom wall and encircling said peripheral edge to define an
internal cavity with an open top end; a first flange extending from
a top edge of said side wall in a radially outward direction, said
first flange having a non-linear inner edge coupled to said side
wall and an outer radial edge aligned with said peripheral edge of
said bottom wall, and a plurality of holes extending through said
first flange and adapted for receiving a fastener for coupling said
electrical device to said box; a second flange extending from said
top edge of said side wall in a radially outward direction, said
second flange having a non-linear inner edge coupled to said side
wall and an outer radial edge aligned with said peripheral edge of
said bottom wall, and a plurality of holes extending through said
second flange and adapted for receiving a fastener for coupling
said electrical device to said box; wherein said holes in said
first flange and said second flange are oriented outwardly from
said side wall.
15. The ceiling box of claim 14, wherein said bottom wall has a
first concave arcuate recessed portion and a second concave arcuate
recessed portion, and where said side wall has a first concave
recessed portion and a second concave recessed portion, said first
flange being coextensive with said first concave recessed portion
of said side wall, and said second flange being coextensive with
said second concave recessed portion of said side wall.
16. The ceiling box of claim 15, wherein said inner edge of said
first flange is integrally formed with said first concave recessed
portion of said side wall; and said inner edge of said second
flange has an inner portion integrally formed with said second
concave recessed portion of said side wall.
17. The ceiling box of claim 16, wherein said first and second
recessed portion of said wall have a substantially arcuate
shape.
18. The ceiling box of claim 16, wherein said first flange and said
second flange have an outer edge aligned with said outer wall.
19. The ceiling box of claim 18, wherein said side wall has a
substantially annular shape with an arcuate portion having a first
radius of curvature; and said first flange and said second flange
have an outer edge with a radius of curvature equal to said radius
of curvature of said side wall.
20. An electrical ceiling box adapted to support an electrical
device, said box comprising: a bottom wall having an outer edge and
a plurality of mounting holes for receiving a fastener for mounting
said box to a support; a substantially continuous side wall
extending from said outer edge of said bottom wall in a direction
substantially perpendicular to said bottom wall and defining an
internal cavity, said bottom wall and said side wall having a
substantially circular shape, said side wall having a first convex
arcuate section with a first end and a second end, a second convex
arcuate section having a first end and second end, a first concave
arcuate section extending between said first end of said first
convex arcuate section and said first end of said second convex
arcuate section, and a second concave arcuate section extending
between said second end of said first convex arcuate section and
said second end of said second convex arcuate section; a first
flange extending outwardly from an upper end of said side wall at
said first concave arcuate section and coextensive with a first
recessed area defined by said first concave arcuate section; a
second flange extending outwardly from an upper end of said side
wall at said second concave arcuate section and coextensive with a
second recessed area defined by said second concave arcuate
section; and wherein said first and second convex arcuate sections
and said outer edges of said first and second flanges form a
continuous circular upper edge of said box.
21. The ceiling box of claim 20, wherein said first and second
flanges are substantially parallel to said bottom wall and coupled
to said first and second concave sections of said side wall,
respectively, to resist bending of said first and second flanges
with respect to said side wall.
22. The ceiling box of claim 21, wherein said first flange has an
outer edge extending between said first end of said first convex
arcuate section and said first end of second convex arcuate
section; and said second flange has an outer edge extending between
said second end of said first convex arcuate section and said
second end of said second convex arcuate sections.
23. (canceled)
24. The ceiling box of claim 20, wherein said first flange has a
plurality of mounting holes for receiving a fastener and
positioning the fastener in said first recessed area outside said
internal cavity of said box; and said second flange has a plurality
of mounting holes for receiving a fastener and positioning the
fastener in said second recessed area outside said internal cavity
of said box.
25. The ceiling box of claim 20, wherein said first flange and said
second flange have an arcuate shaped edge coupled to said first
concave arcuate section and said second concave arcuate section,
respectively.
26. The ceiling box of claim 20, wherein said box is a one piece
integrally formed unit.
27. The ceiling box of claim 26, wherein said box is made of
metal.
28. The ceiling box of claim 20, further comprising a raised
portion in said bottom wall, said raised portion having a threaded
hole for receiving a screw for coupling to a ground wire.
29. The ceiling box of claim 28, wherein said raised portion has a
height less than a height of said side wall and forms a recess on a
bottom side of said bottom wall.
30. The ceiling box of claim 29, wherein said raised portion is
spaced from said side wall.
31. The ceiling box of claim 28, wherein said raised portion is
contiguous with said side wall.
32. The ceiling box of claim 28, wherein said raised portion is
contiguous with said first recessed portion in said side wall, and
where said raised portion is spaced from said bottom wall a
distance less than a distance of said first flange from said bottom
wall.
33. An electrical ceiling box adapted to support an electrical
device and formed as a one piece unitary unit, said box comprising:
a bottom wall with an outer edge and having a plurality of mounting
holes extending therethrough for receiving a fastener for coupling
said box to a support, said bottom wall having a substantially
circular shape with a first convex arcuate portion and a second
convex arcuate portion, said first and second convex arcuate
portions having a first radius, said bottom wall having a first
concave arcuate portion extending between a first end of said first
convex arcuate portion and a first end of said second convex
arcuate portion, and a second concave arcuate portion extending
between a second end of said first convex arcuate portion and a
second end of said second convex arcuate portion, said first and
second concave arcuate portions having a second radius less than
said first radius; a side wall extending from said outer edge of
said bottom wall in a direction substantially perpendicular to said
bottom wall, said side wall terminating at an upper end; a first
flange portion extending from said upper end of said side wall and
overlying said first concave arcuate portion, said first flange
having a plurality of mounting holes for receiving a fastener for
coupling said electrical device to said box, said first flange
having an inner arcuate shaped portion integrally formed with said
side wall; and a second flange portion extending from said upper
end of said side wall and overlying said second concave arcuate
portion, said second flange having a plurality of mounting holes
for receiving a fastener for coupling said electrical device to
said box, said second flange having an inner arcuate shaped portion
integrally formed with said side wall.
34-36. (canceled)
37. The electrical ceiling box of claim 1, further comprising a
raised portion in said bottom wall and having an aperture for
receiving a ground screw, said raised portion forming a recess on
an outer face of said bottom wall.
38. The electrical box of claim 37, wherein said raised portion in
said bottom wall is integrally formed with said recessed portion in
said side wall, said raised portion forming a surface positioned
between said bottom wall and said top end of said side wall.
Description
FIELD OF THE INVENTION
[0001] The present invention is directed to an electrical box and
to an electrical box assembly for supporting an electrical fixture.
More particularly, the invention is directed to an electrical box
having mounting holes within the perimeter of the box for
supporting an electrical fixture such as a ceiling fan or light
fixture.
BACKGROUND OF THE INVENTION
[0002] Electrical boxes are used to mount electrical fixtures such
as ceiling fans and light fixtures. The electrical boxes commonly
have tabs or flanges connected to a side wall that extend into the
center of the box. The tabs include holes for receiving screws for
fastening the electrical fixture to the box and for supporting the
electrical fixture. The electrical box also encloses the wires and
the electrical connections between the power supply and the
electrical fixture. Care must be taken when mounting the electrical
fixture to the electrical box to prevent the mounting screws from
contacting and damaging the electrical wires within the box.
Examples of electrical boxes that have inwardly extending mounting
tabs are disclosed in U.S. Pat. No. 5,988,421 and U.S. Pat. No.
5,883,331.
[0003] Other electrical boxes are also known that include mounting
holes for mounting the electrical box to a support. The mounting
holes can be provided in the bottom wall. In other electrical
boxes, the side wall is formed with a block that has a hole
extending completely through the block to receive the mounting
screw. Examples of such electrical boxes are disclosed in U.S. Pat.
No. 6,646,201; U.S. Pat. No. 6,207,898 and U.S. Pat. No.
6,335,486.
[0004] Many different types of electrical boxes are known in the
art for use as ceiling boxes. Most of the prior ceiling boxes were
designed either specifically for supporting ceiling fans or
specifically for supporting light fixtures. The electrical boxes
that are typically used for ceiling fan support are different than
those used for supporting light fixtures. In particular, electrical
boxes for supporting ceiling fans typically use standard 10-32
screws, while electrical boxes for light fixture support use
standard 8-32 screws. Moreover, Underwriters Laboratories (UL) has
a test that electrical ceiling boxes must pass in order to be used
as the sole support of a ceiling fan. Typically, a conventional
electrical box used for supporting a light fixture or the like can
not be used for supporting a ceiling fan.
[0005] Accordingly, when an electrical box is installed in a
ceiling, the installer must determine whether a ceiling fan or a
light fixture will be attached to the electrical box so that the
correct type of electrical box is installed. If a light fixture
type electrical box is initially installed at a particular location
and then subsequently it is decided that a ceiling fan should be
installed at that location, the original electrical box must
typically either be modified or replaced with an electrical box
which is approved for ceiling fan support. Adapting existing light
fixture boxes for use with ceiling fans is often quite difficult
since light fixture boxes use smaller fasteners and are generally
not strong enough to support fans without substantial
reinforcements or special brackets.
[0006] An electrical box that is approved for ceiling fan support
can also be used to support an electrical device such as a light
fixture. The National Electrical Code permits lighting fixtures to
be supported by electrical boxes proved for ceiling fan support but
not vice-a-versa.
[0007] Adapting existing ceiling fan boxes for use with a light
fixture or the like is not always easily accomplished, since
fasteners for the light fixture are different from the fasteners
use with ceiling fans. For example, fasteners used with light
fixtures generally smaller in diameter than fasteners used with
ceiling fans. Moreover, fixture support fasteners often come in
various colors, finishes and lengths as well as with various
decorative features which may be difficult, if not impossible to
match, in a fastener which can be used with an electrical box
approved for use with ceiling fans. A National Electrical Code
provision (N.E.C. 370-27 (c)) has been proposed which would require
that electrical boxes approved for use with ceiling fans to be
installed at most locations in a building, such as in stairways,
foyers and bathrooms.
[0008] Examples of prior art ceiling fan supports are disclosed in
the following U.S. Pat. No. 4,391,428 to Grimes; U.S. Pat. No.
4,880,128 to Jorgensen; U.S. Pat. No. 4,892,211 to Jorgensen; U.S.
Pat. No. 5,234,119 to Jorgensen et al.; and U.S. Pat. No. 5,407,088
to Jorgensen et al.
[0009] Examples of prior art electrical boxes are disclosed in the
following U.S. Pat. No. 4,315,100 to Haslbeck et al.; U.S. Pat. No.
4,580,689 to Slater; U.S. Pat. No. 4,874,905 to Schnell et al.;
U.S. Pat. No. 4,954,667 to Jorgensen et al.; and U.S. Pat. No.
5,135,411 to Wiley et al. These electrical boxes generally have
mounting tabs that extend inwardly with screw holes that overlie
the internal cavity of the box.
[0010] In view of the above noted problems, there exists a need for
an electrical box approved for use with ceiling fans that can
accommodate both standard light fixture fasteners as well as
ceiling fan fasteners and that can receive mounting screws without
interfering with the electrical box. This invention addresses this
need as well as other needs and problems which will become apparent
those skilled in the art from this disclosure.
SUMMARY OF THE INVENTION
[0011] The present invention is directed to an electrical box and
to an electrical box assembly for supporting an electrical fixture.
The invention is particularly directed to an electrical box having
mounting holes in the perimeter for mounting an electrical fixture
to the box. The mounting holes are positioned so that mounting
screws are outside the wall of the electrical box.
[0012] Accordingly, one aspect of the invention is to provide an
electrical box that is formed as a one piece unitary structure. The
one piece electrical box can be formed from a single sheet of metal
or other material that is stamped into the desired shape.
Alternatively, the electrical box can be molded from a plastic
resin material.
[0013] Another aspect of the invention is to provide an electrical
box with an outwardly extending mounting flange where the box is
capable of selectively supporting a ceiling fan or a lighting
fixture. The mounting flange has a first aperture for receiving a
coupling member such as a screw that is capable of supporting a
ceiling fan. A second aperture is provided in the mounting flange
for receiving a coupling member for mounting a lighting fixture to
the box.
[0014] In one embodiment, the electrical box includes a raised
portion in a bottom wall and having an aperture for receiving a
grounding screw. The raised portion in the bottom wall is spaced
from the bottom wall a distance greater than the length of the
grounding screw so that the ground screw is received within the
cavity formed by the raised portion. The raised portion is also
spaced from the bottom wall a distance less than the height of the
side wall. In one embodiment, the raised portion forms a ground
screw receiving flange that is formed in the side wall of the
electrical box.
[0015] Another aspect of the invention is to provide an electrical
box having a side wall with a non-linear shaped recess and a
mounting flange extending outwardly from the side wall and
overlying the recess.
[0016] The various features of the invention are basically attained
by providing an electrical ceiling box for supporting an electrical
device. The box comprises a bottom wall with a substantially
circular side wall coupled to the bottom wall which has a concave
inner surface, a convex outer surface, and at least one recessed
portion. The recessed portion has a concave outer surface connected
to the convex surface of the side wall and a convex inner surface
connected to the concave inner surface of the side wall.
[0017] The aspects of the invention are also attained by providing
a universal electrical ceiling box adapted to support an electrical
device which comprises a bottom portion having a plurality of
mounting holes adapted for receiving fasteners for mounting the box
to a support surface. The bottom portion has an outer edge which
defines an outer dimension of the box. A side wall extends from the
outer edge in a direction substantially perpendicular to the bottom
portion defining an internal cavity. The side wall has an outer
surface with a first concave recessed portion which extends in an
inward direction with respect to the box. A first flange extends
from an upper end of the side wall substantially parallel to the
bottom portion and overlies the concave recessed portion in the
side wall. The first flange has a plurality of holes which extend
therethrough and are adapted for receiving a fastener for coupling
the electrical device to the box. The holes in the first flange are
aligned with the concave recessed portion and are positioned
outwardly with respect to the side wall.
[0018] The aspects of the invention are further attained by
providing an electrical ceiling box adapted to support an
electrical device, which comprises a bottom wall having a
peripheral edge and a plurality of mounting holes extending
therethrough for receiving a fastener for coupling the box to a
support surface. A side wall extends in a substantially
perpendicular direction from the peripheral edge of the bottom
wall. A first flange extends from the side wall in a radially
outward direction. The first flange has a non-linear inner edge
coupled to the side wall and an outer radial edge aligned with the
peripheral edge of the bottom wall. A plurality of holes extend
through the first flange and are adapted for receiving a fastener
for coupling the electrical device to the box. A second flange
extends from the side wall in a radially outward direction. The
second flange has a non-linear inner edge coupled to the side wall
and an outer radial edge aligned with the peripheral edge of the
bottom wall. A plurality of holes extend through the second flange
and are adapted for receiving a fastener for coupling the
electrical device to the box. The holes in the first flange and the
second flange are oriented outwardly from the side wall.
[0019] The aspects of the invention are still further attained by
providing an electrical ceiling box adapted to support an
electrical device, with the box comprising a bottom wall having an
outer edge and a plurality of mounting holes for receiving a
fastener for mounting the box to a support. A substantially
continuous side wall extends from the outer edge of the bottom wall
in a direction substantially perpendicular to the bottom wall and
defining an internal cavity. The bottom wall and the side wall have
a substantially circular shape. The side wall has a first convex
arcuate section with a first end and a second end. A second convex
arcuate section has a first end and second end. A first concave
arcuate section extends between the first end of the first convex
arcuate section and the first end of the second convex arcuate
section. A second concave arcuate section extends between the
second end of the first convex arcuate section and the second end
of the second convex arcuate section. A first flange extends
outwardly from an upper end of the side wall at the first concave
arcuate section and coextensive with a first recessed area defined
by the first concave arcuate section. A second flange extends
outwardly from an upper end of the side wall at the second concave
arcuate section and is coextensive with a second recessed area
defined by the second concave arcuate section.
[0020] The aspects of the invention are yet further attained by
providing an electrical ceiling box adapted to support an
electrical device. The box comprises a bottom wall with an outer
edge which has a plurality of mounting holes extending therethrough
for receiving a fastener for coupling the box to a support. The
bottom wall has a substantially circular shape with a first convex
arcuate portion and a second convex arcuate portion. The first and
second convex arcuate portions have a first radius. The bottom wall
has a first concave arcuate portion which extends between a first
end of the first convex arcuate portion and a first end of the
second convex arcuate portion. A second concave arcuate portion
extends between a second end of the first arcuate portion and a
second end of the second arcuate portion. The first and second
concave arcuate portions have a second radius less than the first
radius. A side wall extends from the outer edge of the bottom wall
in a direction substantially perpendicular to the bottom wall. The
side wall terminates at an upper end. A first flange portion
extends from the upper end of the side wall and overlies the first
concave arcuate portion. The first flange has a plurality of
mounting holes for receiving a fastener for coupling the electrical
device to the box. A second flange portion extends from the upper
end of the side wall and overlies the second concave arcuate
portion. The second flange has a plurality of mounting holes for
receiving a fastener for coupling the electrical device to the
box.
[0021] The aspects of the invention are still further attained by
providing an electrical box for supporting an electrical device
which comprises a substantially planar bottom wall having an outer
edge and a continuous side wall having a bottom edge connected to
the outer edge of the bottom wall and extending in a direction
substantially perpendicular to the bottom wall and terminating at a
top edge. The side wall forms a substantially circular shape. A
recess in the side wall forms a flange having a hole for receiving
a ground screw. The flange is integral with the side wall and
spaced between the top edge and bottom edge of the side wall.
[0022] Other objects, advantages and salient features of the
invention will become apparent from the following detailed
description of the invention, which taken in conjunction with the
annexed drawings disclose preferred embodiments of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The following is a brief description of the drawings in
which:
[0024] FIG. 1 is a perspective view of the electrical box assembly
in a first embodiment showing a ceiling fan mounted to the
electrical box;
[0025] FIG. 2 is a perspective view of the electrical box of FIG. 1
showing a cover member on the electrical box;
[0026] FIG. 3 is a top plan view of the electrical box of FIG.
1;
[0027] FIG. 4 is a partial cross-sectional view of the flange taken
along line 4-4 of FIG. 3;
[0028] FIG. 5 is a partial cross-sectional view of the flange and
ground screw taken along line 5-5 of FIG. 3;
[0029] FIG. 6 is a bottom perspective view of the electrical box of
FIG. 1;
[0030] FIG. 7 is a top perspective view of the electrical box in
another embodiment; and
[0031] FIG. 8 is a bottom perspective view of the electrical box of
FIG. 7.
DETAILED DESCRIPTION OF THE INVENTION
[0032] The present invention is directed to an electrical box and
an electrical box assembly for supporting an electrical fixture.
The invention is particularly directed to an electrical box having
a plurality of mounting holes within the perimeter of the
electrical box for receiving fasteners for coupling an electrical
fixture to the electrical box. The electrical box typically
includes knock-out plugs and mounting holes.
[0033] Referring to FIGS. 1-6, a first embodiment of the electrical
assembly 10 is shown. Electrical assembly 10 includes an electrical
box 12 for supporting an electrical fixture 14. Electrical fixture
14 is typically a ceiling fan or a light fixture. Electrical box 12
is mounted to a suitable support which can be a ceiling joist or
other solid surface. In the embodiment illustrated, electrical box
12 is coupled to a support bracket 16 extending between a pair of
ceiling joists 18. Bracket 16 as shown includes a pair of
telescoping arms 20 to accommodate variations in the spacing
between joists 18. Arms 20 include a mounting flange 22 at one end
having apertures for receiving fasteners 24 to secure mounting
bracket 16 to joists 18. Typically, fasteners 24 are screws or
bolts that extend into joists 18 to enable mounting bracket 16 and
electrical box 12 to support the intended weight.
[0034] Referring to FIG. 2, electrical box 12 includes a bottom
portion 26 defining a bottom wall and a side portion 28 defining a
side wall to form an open end 30. Bottom portion 26 and side
portion 28 define an internal cavity 32 of electrical box 12 for
containing wires, electrical connections or other electrical
components. It will be understood that the reference to bottom
portion 26 as shown in FIG. 2 refers to the bottom end of cavity 32
regardless of the orientation of electrical box 12 when installed
for use. For example, electrical box 12 as shown in FIG. 1 is
mounted in the ceiling of a structure so that open end 30 faces in
a downward direction and bottom portion 26 is oriented at an upper
end of electrical box assembly 12.
[0035] Bottom portion 26 of electrical box 12 in the embodiment
illustrated has a substantially flat planar surface with a
plurality of apertures 34 and a plurality of knock-out or pry-out
plugs 36. Apertures 34 are positioned to enable electrical box 12
to be attached to the intended support. As shown in FIG. 2,
apertures 34 are positioned to receive a fastener for connecting
electrical box 12 to mounting bracket 16. Preferably, apertures 34
have a dimension to allow fasteners 38 to pass completely through
so that the fasteners can connect with the support surface.
Knock-outs 36 are formed by stamping or punching a partial circular
cut through bottom portion 26. Knock-outs 36 are formed with a tab
40 to connect knock-outs 36 with bottom portion 26. In the
embodiment illustrated, three knock-outs 36 are provided in bottom
portion 26 in locations to supply the electrical wiring to the
cavity 32 of electrical box 12. One or more of knock-outs 36 are
removed by bending tab 40 until broken. Typically, an electric
cable connector 42 is fitted into the opening after the knock-out
is removed for feeding electrical wires into electrical box 12 in a
conventional manner. The electrical cable connector can be a
conduit fitting, a connector for armored cable or a connector for
non-metallic cables.
[0036] Electrical box 12 in the illustrated embodiment has a
substantially circular shape formed by bottom portion 26 and side
portion 28. Bottom portion 26 has a top surface 44 and a bottom
surface 46. Bottom portion 26 has a substantially circular shaped
outer edge 48. Side portion 26 is coupled to outer edge 48 of
bottom portion 26 and extends away from top surface 44 in a
direction substantially perpendicular to the plane of bottom
portion 26. Side portion 26 has an upper edge 50 having a lip 52
for mating with an electrical fixture. Side portion 26 has a height
so that cavity 32 has a volume sufficient to contain electrical
wiring and connectors for connecting a power supply to an
electrical fixture.
[0037] Side portion 28 has at least one and preferably two recessed
portions 54 that form a concave cavity extending inwardly from side
portion 28 toward the center of electrical box 12. A mounting
flange 56 is formed along the upper edge 58 of recessed portions
54. Mounting flange 56 has an inner edge contiguous with the upper
edge 58 of side portion 28 in the recessed portions 54 and is
coextensive with recessed portion 54. Mounting flange 56 has an
outer edge 60 aligned with side portion 28 so that electrical box
12 has a substantially circular shape with a substantially uniform
radius. As shown in FIG. 2, mounting flange 56 is positioned inside
the radius of electrical box 12 and side portion 28.
[0038] Side portion 28 has a first arcuate section 62 having a
convex outer surface 64 and a concave inner surface 66. Side
portion 28 has a second arcuate shaped section 68 having a convex
outer surface 70 and a concave inner surface 72. As shown, first
arcuate section 62 is diametrically opposed to second arcuate
section 68. In the embodiment illustrated, two recessed portions 54
extend between the respective first and second ends of first
arcuate section 62 and second arcuate section 68. Recessed portions
54 are preferably non-linear and have a generally continuous curved
shape extending between the respective ends of the first arcuate
section 62 and second arcuate section 68 of side portion 28. In one
embodiment, recessed portions 54 in the embodiment shown have a
semi-circular shape forming an outwardly facing concave surface 74
and an inwardly facing convex surface 76. As shown in FIG. 3,
recessed portions 54 have a radius less than the radius of side
portion 28.
[0039] Mounting flanges 56 are preferably substantially planar and
extend substantially perpendicular to side portion 28 and recessed
portions 54. Mounting flanges 56 are coplanar with each other and
substantially parallel to bottom portion 26 and define a top
surface of electrical box 12. Each mounting flange 56 has a pair of
spaced-apart mounting holes of different sizes to accommodate
different electrical fixtures. Each mounting flange 56 has a first
mounting hole 78 formed therein with internal threads for
threadedly receiving a screw 80. As shown in FIG. 4, a collar 82
extends from the bottom side of mounting flange 56 surrounding
first mounting hole 78. Collar 82 has an axial length less than the
height of side portion 28 and has an axial length sufficient to
engage the threads of screw 80 to support the weight of the
electrical fixture. Collar 82 can be formed by punching or stamping
hole 78 or by attaching a separate member to flange 56. Electrical
box 12 can include a cover 84 that can be attached to electrical
box 12 by screws 80 when an electrical fixture is not mounted to
box 12. As shown in FIG. 4, screws 80 have an axial length such
that when seated in first mounting hole 78, are spaced a slight
distance from bottom portion 26. In this manner, electrical box 12
can be mounted on the flat surface and screws 80 can be threaded
into first mounting hole 78 without bottoming out against the
support surface. In preferred embodiments, first mounting hole 78
has a threaded internal surface that has a dimension for receiving
a 10-32 screw sufficient for mounting and supporting the weight of
a ceiling fan.
[0040] Each mounting flange 56 includes a second mounting hole 86
that has a diameter slightly less than the diameter of first
mounting hole 78. Preferably, second mounting hole 86 has a
threaded internal bore for threadedly receiving an 8-32 screw for
mounting a lighting fixture or other electrical device to
electrical box 12. Each mounting hole 78 and 86 extend completely
through mounting flange 56 and have a center axis substantially
perpendicular to the plane of mounting flanges 56. In one
embodiment, second mounting hole 86 can have a collar on the bottom
surface of mounting flange 56 for securely receiving mounting
screws.
[0041] Referring to FIGS. 1 and 2, electrical box 12 includes a
ground wire mounting flange 88 having a threaded aperture 90 for
receiving a ground wire screw 92. Screw 92 is threaded into
aperture 90 to connect a ground wire 94 to electrical box 12 as
shown in FIG. 5. Flange 88 is formed by a concave recessed portion
96 in side portion 28. In one embodiment, recessed portion 96 has
an axial height less than an axial height of side portion 28.
Recessed portion 96 is formed by an arcuate shaped section 98
extending substantially perpendicular to bottom portion 26 and has
a concave outer surface 100 and a convex inner surface 102. In one
embodiment, flange 88 is positioned at about a mid-point along the
axial height of side portion 28. Screw 92 has an axial length less
than the height of arcuate section 98 so that screw 92 is
completely received within recessed portion 96. In this manner,
electrical box 12 can be mounted against a flat surface and screw
92 can be threaded through aperture 90 to couple ground wire 94 to
electrical box 12 without interference from the support surface.
Ground screw mounting flange 88 is integrally formed with the side
portion 28 and bottom portion 26. It is desirable to position
flange 88 close to the top edge of side portion 28 while providing
a sufficient space to allow the head of ground screw 92 and ground
wire 94 to sit below the top edge of side portion 28.
[0042] Electrical box 12 can be made of any suitable material such
as plastic or metal. Preferably, bottom portion 26 and side portion
28 has a substantially uniform thickness and is formed as a
one-piece unitary member. In one embodiment, electrical box 12 is
formed from a single sheet of metal that is stamped or pressed into
the desired shape so that each portion has a substantially uniform
thickness.
[0043] In the embodiment illustrated, electrical box 12 has a
substantially circular shape defined by first arcuate section 62
and second arcuate section 68 of side portion 28. First arcuate
section 62 and second arcuate section 68 of side portion 28 and the
arcuate sections of recessed portions 54 form a continuous side
wall of electrical box 12 to contain electrical wiring and
connectors. Recessed portions 54 extend inwardly so that mounting
flanges 56 are spaced outwardly from the side wall and inwardly
from the perimeter of electrical box 12. As shown in FIG. 2,
mounting holes 78 and 86 in mounting flanges 56 are spaced inwardly
from the outer perimeter of electrical box 12 and separated from
the internal cavity 32 of electrical box 12 by the arcuate section
of recessed portions 54. Aperture 90 in flange 88 is also spaced
inwardly from the outer perimeter of electrical box 12 and
separated from cavity 32 by arcuate section 98 to prevent
interference of screw 92 with electrical wiring, connectors or
other components within cavity 32.
[0044] Referring to FIGS. 7 and 8, a second embodiment of the
invention is illustrated. As in the first embodiment, an electrical
box 110 is provided having a substantially circular shape formed by
a bottom wall 112 and a side wall 114. Bottom wall 112 has a
substantially planar surface with a side edge 116. A plurality of
mounting holes 118 are provided in bottom wall 112 for receiving a
fastener such as a screw for mounting electrical box 110 to a
support surface. A plurality of pry-out or knock-outs 120 are
provided for supplying electrical wiring to an inner cavity 122 of
electrical box 110. Side wall 114 is continuous and has a
substantially circular shape.
[0045] As in the previous embodiment, side wall 114 has a first
recessed portion 124 having a continuous first curved section 126.
First curved section 126 has a concave outer surface 128 and a
convex inner surface 130. Side wall 114 further has a second
recessed portion 132 formed by a second curved section 134. Second
curved section 134 has a concave outer surface 136 and a convex
inner surface 138. In one embodiment, first curved section 126 and
second curved section 134 have a semi-circular shape.
[0046] As shown in FIG. 7, side wall 114 is formed by a first
arcuate section 140 having a concave inner surface 142 and a convex
outer surface 144. Side wall 114 further has a second arcuate
section 146 having a concave inner surface 148 and a convex outer
surface 150 as shown in FIG. 8. First curved section 126 of first
recess 124 extends between a first end 152 of first arcuate section
140 and a first end 154 of arcuate section 146. Curved section 134
of second recessed portion 132 extends between a second end 156 of
arcuate section 140 and a second end 158 of arcuate section 146. In
this manner, first and second arcuate sections 140 and 146 and
curved sections 126 and 134 form a continuous wall of electrical
box 110.
[0047] Curved section 126 of first recess portion 124 has a height
substantially equal to the height of first arcuate section 140 and
second arcuate section 146 of side wall 114 and terminates at an
upper edge. In the embodiment illustrated, curved section 126 has a
substantially semi-circular shape with a radius less than a radius
of electrical box 110. A mounting flange 160 is integrally formed
with curved section 126 and extends parallel to bottom wall 112.
Mounting flange 160 has an inner edge contiguous with curved
section 126 and an outer edge aligned with a perimeter of
electrical box 110 and extending between first end 152 of arcuate
section 140 and first end 154 of arcuate section 146. Mounting
flange 160 includes a first mounting hole 162 having internal
threads for receiving a mounting screw. As shown in FIG. 8, a
threaded collar 164 extends from a bottom surface of mounting
flange 160 and surrounds mounting hole 162. A second threaded
mounting hole 166 is formed in mounting flange 160 and having a
diameter slightly less than the diameter of first mounting hole
162.
[0048] In the embodiment of FIGS. 7 and 8, a ground screw mounting
flange 168 is contiguous with the curved section 134 of second
recessed portion 132. Flange 168 is formed by a recess 170 that is
adjacent and contiguous with second recessed portion 132.
[0049] Recess 170 has a curved wall section 172 extending between
second end 158 of arcuate section 148 and curved section 134 of
second recess 132. Curved section 172 extends in a direction
perpendicular to bottom wall 112 and has a height less than side
wall 114. Flange 168 includes a threaded aperture 174 to receive a
screw 175 for connecting a ground wire to electrical box 110.
Flange 168 is spaced from the top edge of side wall 114 a distance
so that ground screw 175 is below the top edge when ground screw
175 is seated against flange 168 to clamp a ground wire to flange
168. Flange 168 is spaced from bottom wall 112 a distance to
prevent screw 175 from contacting a support surface when screw 175
is seated against flange 168.
[0050] A second mounting flange 176 overlies second recessed
portion 132 and is connected to curved section 136. Flange 176 has
a curved inner edge 178 and a curved outer edge 180. The ends of
inner edge 178 and outer edge 180 are connected to the second ends
156, 158 of arcuate sections 140, 146, respectively. Mounting
flange 176 includes a first threaded hole 182 with a collar 184 on
the bottom side of flange 176 and a second threaded hole 186.
[0051] In each of the embodiments, the electrical box is formed
from a single sheet of metal that is stamped or pressed into the
desired shape. The electrical box has a continuous side wall with
mounting flanges extending outwardly from the side wall but
maintained within the overall perimeter of the electrical box. The
mounting holes in the flanges receive mounting screws or other
fasteners that can extend through the flange for mounting an
electrical fixture to the box without interfering with the
electrical wires, connectors or other components within the cavity
of the electrical box.
[0052] While various embodiments have been selected to illustrate
the invention, it will be understood by those skilled in the art
that various changes and modifications can be made without
departing from the scope of the invention as defined in the
appended claims.
* * * * *