Abstract:
A ceiling fan box adapted to be mounted on a structural member, such as a ceiling joist, and adapted to provide a ceiling fan direct securement to the structural member. The ceiling box includes a body having a lower surface and a pair of spaced apart opposed side members defining a recess therebetween for receiving the structural member therein. An aperture formed through the lower surface for receiving a fastener therein for securement to the structural member for supporting the body thereon. A pair of spaced apart openings formed through the lower surface for receiving a respective pair of fan supporting fasteners therethrough for directly securing a fan to the structure member.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application is a divisional of U.S. patent application Ser. No. 10/146,995, filed May 16, 2002; and claims priority to U.S. Provisional Application No. 60/293,439 filed on May 24, 2001 and U.S. Patent Application No. 60/374,895, filed on Apr. 23, 2002. 
     
    
     FIELD OF THE INVENTION:  
       [0002]     The present invention relates generally to an electrical box mountable on the ceiling for supporting a ceiling fan. More particularly, the present invention relates to a ceiling fan box which is mountable directly to a ceiling joist.  
       BACKGROUND OF THE INVENTION  
       [0003]     In order to mount ceiling fans, ceiling fan boxes are typically used. A ceiling fan box which is attachable to a ceiling joist or other support in the ceiling generally serves two functions. First, it encloses the electrical wire terminations which are made between the ceiling fan and the electrical power run to the ceiling fan. Second, the ceiling fan box supports the ceiling fan during operation. Such boxes may be used with existing construction (old work) where the ceiling fan is being installed in a finished area, or during construction (new work) where the ceiling fan may be installed prior to installation of the ceiling. In either case, it is necessary to attach the ceiling fan box to the ceiling joist or other ceiling supported structure. It may be appreciated that working overhead in a ceiling is difficult. Thus, the method of attaching the ceiling fan box to the ceiling joist, is critical with respect to both convenience and time savings.  
         [0004]     Moreover, the ceiling fan box must be of construction which can withstand the dynamic load imparted by the ceiling fan which is attached thereto. Such dynamic loads may also include loads imparted by an unbalanced ceiling fan.  
         [0005]     It is therefore desirable to provide a ceiling fan box which may be easily attached to a ceiling structure such as a ceiling joist and which securely supports the ceiling fan therefrom. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0006]      FIG. 1  is a top perspective view of an improved electrical ceiling fan box of the present invention.  
         [0007]      FIG. 2  is a lower perspective showing of the electrical ceiling fan box of  FIG. 1 .  
         [0008]      FIGS. 3 and 4  show respectively a top perspective and bottom perspective view of a further embodiment of the electrical ceiling fan box of the present invention.  
         [0009]      FIGS. 5 and 6  show top and bottom perspective views, respectively of a still further embodiment of the electrical ceiling fan box of the present invention.  
         [0010]      FIG. 7  shows a top perspective view of another embodiment of the electrical ceiling fan box of the present invention.  
         [0011]      FIG. 8  shows a top plan view of the ceiling fan box of  FIG. 7 .  
         [0012]      FIG. 9  shows a top perspective view of yet another embodiment of the electrical ceiling fan box of the present invention.  
         [0013]      FIG. 10  shows a top perspective view of still yet another embodiment of the electrical ceiling fan box of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0014]     The present invention provides a ceiling fan box which is attachable to a ceiling joist for supporting a ceiling fan therefrom. The electrical ceiling box of the present invention is an improvement in boxes of the type generally shown and described in U.S. Pat. No. 5,234,119, issued Aug. 10, 1993 and U.S. Pat. No. 4,874,905, issued Oct. 17, 1989, the disclosures of each are being incorporated by reference herein for all purposes.  
         [0015]     Referring now to  FIGS. 1 and 2 , an embodiment of the electrical ceiling box of the present invention is shown. While referred to as a box, the ceiling fan box  10  of the present invention is general cylindrical in shape and includes a body  12  having a planar lower surface  14 , a pair of upstanding side members  16  and  18  on either side of lower surface  14 . The side members  16  and  18  and the lower surface  14  define a generally U-shaped recess  20  for accommodating a ceiling joist (not shown) therein. Side members  16  and  18  include facing side walls  16   a  and  18   a  which are spaced apart a distance generally equivalent to the width of a ceiling joist. The ceiling joist is inserted into recess  20  and is frictionally retained therein by frictional engagement with walls  16   a  and  18   a . In order to assist in the frictional retention of the body  12  about the joist, the side walls  16   a  and  18   a  include a plurality of spaced apart elongate outwardly extending ribs  22  therealong. The ribs  22  help to provide frictional engagement with the opposed side surfaces of the joist which is inserted into recess  20 . Side members  16  and  18  further include a plurality of wire entry apertures  24  which may be enclosed by frangibly removable covers  24   a . The apertures  24  permit insertion of wires into hollow cavities  26  defined by side members  16  and  18 .  
         [0016]     As shown in  FIG. 2 , wire terminations for attachment to a ceiling fan may be made in the recesses  26  and the area  28  defined by the opposite side  14   a  of lower surface  14 . Side members  16  and  18  further include knockout openings  30  and  32 , respectively, which include frangibly removable covers  30   a  and  32   a  which are also designed to permit wire entry. Once the covers are removed, the knockouts can support an electrical nipple which facilitates wire entry.  
         [0017]     Lower surface  14  includes a centrally located aperture  40  and a pair of elongate openings  42  and  44 . Openings  42  and  44  extend from adjacent the peripheral edge of body  12  and extend through surface  14 .  
         [0018]     Box  10  may be inserted onto a stud by placing the box in a straddling position around the ceiling joist with the ceiling joist being frictionally retained within recess  20  thereof. Frictional retention is provided by the engagement between the walls  16   a  and  18   a  of side members  16  and  18  with the opposed side surface of the joist. The box  10  is inserted until the lower surface  14  rests against the lower edge of the joist. In this position, while the outlet box is frictionally retained on the joist, the outlet box may be more securely fastened thereto by inserting an appropriate fastener such as a wood screw through aperture  40  and into the face of the joist.  
         [0019]     Once the box is securely fastened to the joist, the ceiling fan may be supported directly to the joist through the box. This is accomplished by inserting the fastening hardware, such as wood screws, of the ceiling fan through openings  42  and  44  and directly into the face of the joist against which the box is supported. The elongate openings  42  and  44  allow for adjustable positioning so as to help properly align the ceiling fan. Thus, the ceiling fan is supported directly to the joist through the ceiling box and the ceiling box need not be relied upon for support of the ceiling fan. The box, however, provides an adequate enclosure for housing the wire terminations to the ceiling fan.  
         [0020]     The present invention further provides a pair upwardly directed spaced apart extensions  50  along each side wall  16   a  and  18   a  of side members  16  and  18 . Extensions  60  are flush with side walls  16   a  and  18   a  so that they are positioned along the opposed sides of the joist. Each extension  60  includes an aperture  62  therethrough through which an appropriate fastener such as a wood screw may be inserted to more securely retain the box on the joist.  
         [0021]     Referring now to  FIGS. 3 and 4 , a further embodiment of the present invention is shown. The embodiment in  FIGS. 3 and 4  is similar to the embodiment shown in  FIGS. 1 and 2 , however, a 45° opening is shown in the lower portion of the side members to allow insertion of a wood screw or similar fastening hardware to secure the box to the sides of the joist inserted therein.  
         [0022]      FIGS. 5 and 6  show a still further embodiment of the box of the present invention. The embodiment of  FIGS. 5 and 6  is substantially similar to the embodiment of  FIGS. 3 and 4 , but provides a different arrangement for the apertures for mounting the ceiling fan.  
         [0023]     Another embodiment of the box of the present invention as shown in  FIG. 7  is substantially similar to the embodiment of the previous figures, but provides a screw retention feature  85  to temporarily hold screws  80  to the ceiling fan box  10   f  prior to use. In this embodiment, as shown in  FIG. 7 , the screw retention structure  85  preferably includes two pair of flexible prongs, uprights or clips  81  which removably secure the screws  80  against the wall structure  84  of the elongated boss defining opening  44   f . Screw  80  is secured by clips  81 , which wrap around a portion of the screw and cause the screw to press against the wall structure  84 . The distance between the clips  81  and the wall structure  84  is far enough for placement of a screw without undue stress and tension of the wall structure  84  and clips  81 ; yet it is close enough to removably secure the screw  80  but prevent dislodgement during shipment.  
         [0024]     One aspect of the retention feature  85  is that the screws  80  are detachable by a user, such as an electrician, to employ during installation of the electrical box  10   f . While the screw retention feature  85  is shown as using the wall structure  84 , it should also be appreciated that other structures of the box, such as central boss  86 , may be used to provide the screw retention feature.  
         [0025]     As shown in  FIG. 8 , box  10   f  has a central opening  40   k  extending through central boss  86 . The opening  40   k  is provided with a flattened surface  43   k  such that the aperture  40   k  appears to have a “D” shape. Such “D” shaped opening provides for further screw holding capability. It should be appreciated that the flat surface  43   k  may be located at any surface defining the aperture  40   k.    
         [0026]     Yet another embodiment of the ceiling fan box is shown in  FIG. 9 . Box  10   g  is substantially similar to the box of  FIGS. 7 and 8 , but provides a different shape to the body of the electrical box. The box  10 g is generally cylindrical in shape and includes a body  12   g  having a rim  90  extending circumferentially around the upper end  14   g  thereof. A pair of side members  16   g  and  18   g  extend downwardly from either side of the upper end  14   g . The rim  90  has a diameter extending outwardly radially beyond the outer surfaces of side members  16   g  and  18   g  such that the side members  16   g  and  18   g  appear to be recessed within the rim  90 .  
         [0027]      FIG. 10  shows yet still another embodiment of the present invention.  FIG. 10  is substantially similar to  FIGS. 7 and 8 , however, a collar or flange  100  is shown extending outwardly around the body  12   h  of the box  10   h . Flange  100  extends fully circumferentially around the periphery of the upper end  14   h  of the box  10   h . A strip of insulating material, such as foam  101 , may be provided on the upper surface of flange  100  to create a seal in conjuction with the ceiling wallboard for enhancing energy efficiency.