Abstract:
A Specialized Outlet Box Mounting Bracket is disclosed. The bracket provides a convenient mounting platform for a 3½ inch deep outlet box within a conventional stud wall. The bracket eliminates the requirement for special, labor-intensive installation methods by installing easily between a pair of structural studs at standard spacing. The bracket further provides two installation options—one for a single-sheet drywall wall construction, and an additional one for a double-sheet drywall wall construction. The bracket&#39;s outlet box reservoirs are configured to provide rigid backing support for the deep outlet boxes with the bracket being stamped out of a single piece of flat metal stock, and therefore being extremely material-efficient.

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates generally to electrical enclosures and related structures and, more specifically, to a Specialized Outlet Box Mounting Bracket. 
   2. Description of Related Art 
   Recent developments related to the wiring requirements for institutional fire alarm systems has created a unique problem in the construction industry. Institutional fire alarm assemblies are (typically wall-mounted) audio and visual alarm locations located throughout commercial and institutional buildings. A typical fire alarm assembly and junction box (“outlet box”) are shown in  FIG. 1A . Under previous building standards, the electrical junction boxes  12  used for fire alarm assemblies  10  was a conventional square junction box having a depth  14  of 2⅛ inches deep. These “shallow” boxes have conventionally been attached to framing studs during construction via a bracket system such as that described by Delmore et al., U.S. Pat. No. 4,757,967. The Delmore bracket enabled the shallow box to be quickly mounted between a pair of conventional framing studs quickly, and still permitted the box  12  to be slid from side to side in order to place it in exactly the desired position between the studs.  FIG. 1B  depicts a outlet box assembly  12  if mounted directly to a stud  16  without the benefit of the Delmore bracket. Clearly, once installed, the surface of the studs is covered with one or two layers of drywall  18 . 
   With the new requirements, a box depth of 3½ inches is mandated. This has made the old shallow box difficult to use, and the new deeper box hard to install.  FIG. 2  depicts one approach to using a shallow box to provide adequate overall box depth. Items called “box extenders”  22  are available for increasing the depth of the conventional shallow boxes. The box extender  22  is basically the same shape and size as the outlet box  20 , but without a back (i.e. the back is open). It is fastened to the front of the outlet box  20  with the available screws. When the outlet box assembly  12  is complete, the depth of the assembly  12  will be equal to the outlet box depth  32  plus the box extender depth  30 . 
   The problem with using a box extender  22  is that the box extender  22  does not mount exactly square with the outlet box  20 , and therefore leaves the fire alarm assembly out of level. Correcting this lack of level requires considerable effort, many times to include removing drywall, straightening the box, then patching the drywall and finish texture. 
   What is needed, therefore, is a mounting device and/or system that makes installation of the new, deeper fire alarm assembly outlet boxes to be more easily installed. 
   SUMMARY OF THE INVENTION 
   In light of the aforementioned problems associated with the prior devices and systems, it is an object of the present invention to provide a Specialized Outlet Box Mounting Bracket. The bracket should be configured to provide a convenient mounting platform for a 3½ inch deep outlet box within a conventional stud wall. The bracket should eliminate the requirement for special, labor-intensive installation methods by installing easily between a pair of structural studs at standard spacing. The bracket should further provide two installation options—one for a single-sheet drywall wall construction, and an additional one for a double-sheet drywall wall construction. The bracket&#39;s outlet box reservoirs should be configured to provide rigid backing support for the deep outlet boxes with the bracket being stamped out of a single piece of flat metal stock, and therefore being extremely material-efficient. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The objects and features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages, may best be understood by reference to the following description, taken in connection with the accompanying drawings, of which: 
       FIG. 1A  is a perspective view of a conventional junction box assembly and fire alarm assembly; 
       FIG. 1B  is a perspective view of a conventional junction box assembly as it is installed within a stud wall; 
       FIG. 2  is a perspective view of a conventional box extender used with a shallow junction box; 
       FIG. 3  is a perspective view of a preferred embodiment of a specialized junction box mounting bracket of the present invention; 
       FIG. 4  is a front view of the mounting bracket of  FIG. 3 ; 
       FIGS. 5A and 5B  are cutaway side views of the bracket of  FIGS. 3 and 4 ; 
       FIGS. 6A and 6B  are top and bottom views of the bracket of  FIGS. 3-5 ; and 
       FIGS. 7A and 7B  are cutaway side views of the bracket of  FIGS. 3-6 . 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor of carrying out his invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the generic principles of the present invention have been defined herein specifically to provide a Specialized Outlet Box Mounting Bracket. Throughout the ensuing description, the term “Outlet box” will be used extensively an is intended to mean “junction box” in each use. 
   The present invention can best be understood by initial consideration of  FIG. 3 .  FIG. 3  is a perspective view of a preferred embodiment of a specialized junction box mounting bracket  40  of the present invention. The bracket  40  is preferably formed from a single sheet of galvanized steel or other suitable material in order to provide a versatile, strong, yet low-cost device. The bracket  40  is defined by a face plate  42  having a first mounting fin  47 A and a second mounting fin  47 B extending from opposite sides thereof. Each mounting fin  47  has at least one mounting aperture (e.g.  48 A and  48 B) formed in it for easy installation into a framing stud when the mounting bracket  40  is used. The fins  47  and apertures  48  are in spaced relation to cooperate with conventional framing spacing, such as at sixteen inches on-center. 
   The face plate  42  has a first outlet box aperture  46 A formed in it. A first outlet box reservoir  44 A is accessed through this aperture  46 A. The aperture  46 A is dimensioned to accept a new deep outlet box therein. An outlet box inserted into the reservoir  44 A is retained in place by a first upper L-bracket  50 A and a first lower L-bracket  52 A extending backwardly from the face plate  42 . To reduce material costs and manufacturing costs, the first and second L-brackets are actually formed from the material cut from the face plate  42  in order to form the first outlet box aperture  46 A. Each L-bracket is only cut on three sides and then pressed into the L-shaped form shown. 
   Similarly, a second outlet box aperture  46 B is cut into the face plate  42  beside the first outlet box aperture  46 A. A second outlet box reservoir  44 B is accessible through the second outlet box aperture  46 B, and is bounded by a second upper L-bracket  50 B and a second lower L-bracket  52 B. The two L-brackets  50 B and  52 B are also preferably formed from the material cut to make the second outlet box aperture  46 B. The second outlet box reservoir  44 B is configured to accept and support a new deep-depth outlet box therein. 
   The two reservoirs  44 A and  44 B are of differing depths so that the bracket  40  can accommodate walls having either a single layer of drywall or a double layer of drywall. One of the reservoirs will have a depth of about 2.25 inches to accommodate an outlet box having a depth of 3.5 inches that will protrude 1.25 inches beyond the face of the studs (allowing for two layers of 0.75 inch drywall); another of the reservoirs will have a depth of about 2.75 inches so that the deep outlet box will protrude 0.75 inches beyond the face of the studs to allow for one layer of drywall. Of course, the bracket can be flipped over (side-for-side) so that the reservoir having the desired depth is either on the right or the left. Now turning to  FIG. 4 , we can continue to examine this novel and very useful device. 
     FIG. 4  is a front view of the mounting bracket  40  of  FIG. 3 . The bracket  40  is shown as it would be installed between a pair of studs  16  in a conventional stud wall. Fasteners would be driven through the mounting apertures formed on the mounting fins to secure the bracket  40  in place. 
   As can be seen here, the backing plates  56 A,  58 A are of different lengths than the backing plates  56 B and  58 B. This is because more material is used for the side plates in the second outlet box reservoir  44 B than is used for the first outlet box reservoir  44 A. Each of the backing plates  56 A,  56 B,  58 A and  58 B have apertures formed in them to accommodate fasteners passing therethrough to secure the outlet box to the backing plates. 
   Also depicted in this view are the upper stiffening lip  54 A and the lower stiffening lip  54 B. These lips  54  are formed by slightly bending back the face plate  42  along the top and bottom edges, while leaving the side mounting fin areas unbent. The stiffening lips  54 A and  54 B provide desired rigidity to the bracket  40  without the need for complex structure or manufacturing processes. Turning to  FIGS. 5A and 5B , we can continue to examine this unique structure. 
     FIGS. 5A and 5B  are cutaway side views of the bracket  40  of  FIGS. 3 and 4 . Two features are clear here—that the first reservoir depth  64 A is shallower than is the second reservoir depth  64 B. Furthermore, cross-sections of the upper and lower stiffening lips  54 A and  54 B are shown so that their preferred structure is clearly depicted. 
     FIGS. 6A and 6B  are top and bottom views of the bracket  40  of  FIGS. 3-5 . In  FIG. 6A , the upper L-shaped brackets  50 A and  50 B are clearly depicted. In  FIG. 6B , the lower L-shaped brackets  52 A and  52 B are clearly depicted. Again, in its preferred form, all of the L-shaped brackets are formed from the material cut out to form the outlet box apertures, which is then bent into an L shape. The L-shaped brackets, therefore, all have an end that extends from the face plate, and an end opposite to this attached end that is free. Finally turning to  FIGS. 7A and 7B , we can see how a deep outlet box inserted into each of the two reservoirs would appear. 
     FIGS. 7A and 7B  are cutaway side views of the bracket of  FIGS. 3-6 . As shown, two layers of drywall  18  have been applied over the face plate  42  (and studs, of course). The outlet box  20 , would have been installed into the first reservoir  44 A prior to the drywall installation; the outlet box depth  66  of 3.5 inches would leave the rim of the box  20  extending out from the front of the studs a distance equal to a pair of sheets of drywall. 
   As the drywall is being installed, a wall opening  68  is cut into each piece of drywall (around the already-installed outlet box  20 ). The depth of the first reservoir  44 A results in the outlet box  20  rim being essentially even with the outer surface of the wall. 
   Similarly, the second outlet box reservoir  44 B has a depth  64 B that will result in an installed deep outlet box rim being equal to the outer surface of a wall constructed from a single sheet of drywall  18 . 
   Those skilled in the art will appreciate that various adaptations and modifications of the just-described preferred embodiment can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.