Abstract:
Improvements in a universal box mounting adapter and system for mounting 4″ and 4 11/16″ boxes directly to stud using side tabs. In addition, the UBM features a bendable back support for rigid installations. The novel feature of this product is the integral conduit support flange. This flange features slots and pinholes for use with a wide assortment of conduit supporting accessories. The adapter can be used with a kick bracket for placing junction boxes between studs at desired heights. The kick bracket can be mounted either vertically or horizontally and features pinholes along the length for adjusting the location of the adapter. Along with integral wings for supporting the kick bracket when installed vertically, the adapter and kick bracket make up a system of configurations to meet the needs of an installer. The adapter is configurable for installing multiple boxes between either 16″ or 24″ studs.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    Not Applicable 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable 
       THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT 
       [0003]    Not Applicable 
       INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC 
       [0004]    Not Applicable 
       BACKGROUND OF THE INVENTION 
     Field of the Invention 
       [0005]    This invention relates to improvements in a universal box mounting adapter and system. More particularly, the present universal box mounting adapter is an adapter for mounting 4″ and 4 11/16″ electrical boxes directly to studs using side tabs. The universal box mounting adapter further includes bendable back supports and integral conduit support flanges. 
         [0006]    Description of Related Art including information disclosed under 37 CFR 1.97 and 1.98: 
         [0007]    Houses and buildings require connection of electricity to operate light appliances and equipment. To connect these devices an installer uses electric boxes that are mounted upon. Walls are generally formed against wooden or metal studs, although metal of a channel configuration is particularly common in modern residential and commercial applications. In such applications, electric boxes tend to be supported by assemblies, frames or brackets that are in turn mounted to the metal studs or to other components that rest directly on the floor. 
         [0008]    Electric boxes are supported in many fashions within the walls on supporting studs. The electrical boxes may be fastened directly to a wall stud, albeit this method is generally discouraged on metal studs for practical reasons. The electrical boxes may rest within a bracket that attaches along one side to a vertical wall stud. Traditional methods of mounting such electric boxes therefore require electricians or the like to maintain a complete stock of each type of mounting bracket that may be necessary as the situation demands. 
         [0009]    There are a number of patents and or publications have been made to address these issues. Exemplary examples of patents and or publication that try to address this/these problem(s) are identified and discussed below. 
         [0010]    U.S. Pat. No. 4,964,525 issued on Oct. 23, 1990 to Donald T. Coffey et al., discloses an Electrical Box Mounting Bracket. This bracket is configured to grasp a side stud or can span across two studs if the studs a spaced close enough together. This patent is only configured for a single electrical box, and does not include a system for securing multiple junction boxes, it further does not provide support for conduit and does not includes pin holes for multiple mounting configurations. 
         [0011]    U.S. Pat. No. 7,439,443 issued on Oct. 21, 2008 to Cong Thanh Dinh discloses a Mounting Bracket for Electrical Boxes. The bracket can universally be secured to a stud wall with both front and side holes for nailing or screwing the bracket to the stud. This bracket has limited versatility to accept conduit or other mounting accessories. These limitations provide limited options for an installer to mount the bracket in different configurations to studs. 
         [0012]    U.S. Pat. No. 8,403,289 issued on Mar. 26, 2013 to Eric R. Rinderer discloses a Universal Electrical Box Mounting Device. This mounting system is predominately configured for mounting of a single adapter to metal stud walls. If multiple adapters are used the multiple adapters are first secured to separate strip that is secured to the metal studs. While some configurations have an enlarged hole for a conduit, the opening does not securely hold the conduit to prevent undesirable movement of the conduit within the opening. The mounting device further requires a separate strip to mount an electrical box between stud walls. 
         [0013]    What is needed is a universal box mounting adapter and system. Disclosure found in this document provides a solution with an adapter for mounting 4″ and 4 11/16″ boxes directly to studs using side tabs. 
       BRIEF SUMMARY OF THE INVENTION 
       [0014]    It is an object of the universal box mounting adapter and system to mount 4″ and 4 11/16″ boxes directly to studs. The side tabs include a plurality of holes where screws can be inserted for securing the universal box mounting adapter onto wood or metal studs. When the universal box mounting adapter is secured it provides a stable base for connecting an electrical junction box behind the universal box mounting adapter and also provide a mounting front for a finish plate where drywall, sheetrock or similar sheet material can be used for the finished wall surface. The front plate has keyholes for accommodating 4S and 5S boxes. 
         [0015]    It is an object of the universal box mounting adapter and system to include an integral conduit support flange. The integral conduit support flange maintains the position of rigid conduit as the rigid conduit connects to the universal box mounting adapter. The support allows an installer to secure a variety of different accessories to the universal box mounting adapter to accommodate conduit securing devices such a tie wire, one-hole straps, conduit clips, Colorado jim clips, zip ties and bat wings. 
         [0016]    It is an object of the universal box mounting adapter and system for the integral conduit support flange to have slots and pinholes for use with a wide assortment of conduit supporting accessories. 
         [0017]    It is another object of the universal box mounting adapter and system to operate with a universal box mounting adapter kick bracket for placing junction boxes between studs at a desired height. The kick bracket provides horizontal and vertical installations as well as versatile positioning of the universal box mounting adapter system. 
         [0018]    It is another object of the universal box mounting adapter and system to allow for mounting in either a vertical or a horizontal orientation. Features pinholes along the length for adjusting the location of the universal box mounting adapter. 
         [0019]    It is still another object of the universal box mounting adapter and system to have integral wings for supporting the kick bracket when installed in a vertical orientation, the universal box mounting adapter and kick bracket make up a system of configurations to meet the needs of an installer. 
         [0020]    It is still another object of the universal box mounting adapter and system to operate with 16″ or 24″ on center studs. Building and houses are usually constructed with studs placed 16″ or 24″ on center and electrical outlets can be adjacent to the studs or placed between the studs. The universal box mounting adapter can further be configures to accept multiple junction boxes between the studs. A floor stand can also be used to set the universal box mounting adapter 15″ or 18″ from the floor. 
         [0021]    Various objects, features, aspects, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
         [0022]      FIG. 1  shows a perspective view of the universal box mounting adapter and system. 
           [0023]      FIG. 2A-2B  shows perspective views of the universal box mounting adapter kick bracket. 
           [0024]      FIG. 3A-3D  show perspective views installation of a single universal box mounting adapter. 
           [0025]      FIG. 4A-4D  show perspective views installation of two universal box mounting adapter. 
           [0026]      FIG. 5A-5B  show perspective views of a triple universal box mounting adapter on a floor stand and an extender with a conduit hook. 
           [0027]      FIG. 6A-6D  show perspective views installation of a triple universal box mounting adapter. 
           [0028]      FIG. 7  shows a perspective view of a four position universal box mounting adapter. 
           [0029]      FIG. 8A-8E  show perspective views of different conduit supporting options. 
           [0030]      FIG. 9  shows a perspective view of a universal box mounting adapter installed on a metal stud with secured conduit. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0031]      FIG. 1  shows a perspective view of the universal box mounting adapter  20  and system secured to a stud  21 . The stud can be either a wood or metal stud for 4″ or 6″ thick wall. The front mounting flanges  31  and  32  face of the universal box mounting adapter  20 . These mounting flanges  31  and  32  have a plurality of holes  80 ,  81 ,  82 ,  83 . The holes  80 ,  81 ,  82 , and  83  allow for mounting the universal box mounting adapter  20  directly on to a stud. The front mounting flanges  31  and  32  have a notch  33  to identify the center line of the universal box mounting adapter  20  on the flange(s)  30 . Relief bends  37  recess face  35  and provide clearance for securing hardware for an electrical box cover (not shown). 
         [0032]    The center of the universal box mounting adapter  20  is open  36  within the boundary  34  for access to wiring within the universal box mounting adapter  20 . This face  35 , has a plurality of mounting holes  71 ,  72 ,  73  and keyhole slots  70  for securing an electrical box cover. The bottom of the face  35  has a tab  38 . The face  35  bends  39  to an open  94  horizontal support  95 . 
         [0033]    The horizontal support  95  has vertical sides  90  and front-facing tabs  92  with mounting or securing holes  93 . The vertical sides  90  also have holes  91  for securing our mounting the universal box mounting adapter  20 . The holes  91  can be used to screw the universal box mounting adapter  20  into the side of a stud  21 . The center  94  of the horizontal support  95  is open. The back of the horizontal support has central tab  50  and two joined tabs  61  and  62 . 
         [0034]    The central tab  50  is secured to the horizontal support  95  with an open hinge  51 . The open hinge allows the central tab  50  to easily bend on the horizontal support  95 . The central tab  50  further includes a plurality of open slots  52 ,  53  and  54  that allows the central tab  50  to be easily bent at these locations without special tools. The central tab  50  can be bent back horizontally and further bent at slot  53  to fit within a 6-inch stud wall where the end portion  55  is oriented vertically. The central tab  50  is an adjustable back support. 
         [0035]    The two joined tabs  61  and  62  are secured to the horizontal support  95  with open hinges  63  and  64 . These two joined tabs  61  and  62  are joined at the top through tab  60  that promotes uniform bending of tabs  61  and  62 . Tab  60  joins to the tabs  61  and  62  through open hinges  65  and  66  that promote uniform bending of the top tab  60 . The top tab  60  provides a plurality of holes  68  and a slot  67  for a plurality of conduit supporting options as shown and described in  FIGS. 8A-8E . 
         [0036]      FIG. 2A-2B  shows perspective views of the universal box mounting adapter kick bracket  19 . The kick bracket  19  allows the universal box mounting adapter  20  to be secured between studs and further can be installed in either a vertical orientation as in  FIG. 2A  or a horizontal orientation and in  FIG. 2B . The kick bracket  19  has a support face  100  and an open area  104  where one or more universal box mounting adapter  20  are installed. The kick bracket  19  has a bent tab  101  that is bent  102  along a weakened area(s)  102  of the face  100 . The bent tab  101  can be placed under or around a stud or footer. The kick bracket  19  has a plurality of pin holes  104  and  105  that provide multiple securing locations for the kick bracket  109 . Holes  103  and  107  are used to secure the kick bracket  19  to footers, studs and or fire breaks. The top of the kick bracket  19  has extended tabs to extend beyond the body of the face to secure the kick bracket  19  to studs that exist outside the face  100 . On the side of the kick bracket  19  a breakable wing  18  can be removed from the lick bracket  19  to provide orthogonal support to the kick bracket  19  and the universal box mounting adapter  20 . 
         [0037]    The breakable wing  18  has a plurality of pin holes  111  and  113  for securing the breakable wing  18  to stud walls and a plurality of other holes  112  for securing the universal box mounting adapter  20  or for securing the breakable wing  18  to a stud. The breakable wing  18  further has imprints  14  or indicia  115  for consistent box placement of the universal box mounting adapter  20 . A number different installation options are possible for mounting a single or two universal box mounting adapter(s)  20 . 
         [0038]      FIG. 3A-3D  show perspective views installation of a single universal box mounting adapter.  FIG. 3A  shows the universal box mounting adapter  20  mounted to a vertical stud  21 .  FIG. 3B  shows a universal box mounting adapter  20  secured to a vertical kick bracket  19  and the kick bracket  19  secured to a vertical stud  21  and to a footer.  FIG. 3C  shows a universal box mounting adapter  20  mounted to a vertical kick bracket  19 . The vertical kick bracket  18  is secured with a wing  18  between two vertical studs  21  and a footer.  FIG. 3D  shows a universal box mounting adapter  20  secured to a horizontal kick bracket  19  and the horizontal kick bracket is secured to two vertical studs  21 . 
         [0039]      FIG. 4A-4D  show perspective views installation of two universal box mounting adapter.  FIG. 4A  shows two universal box mounting adapters  20  mounted to a vertical stud  21 .  FIG. 4B  shows two universal box mounting adapters  20  secured to a vertical kick bracket  19  and the kick bracket  19  secured to a vertical stud  21  and to a footer.  FIG. 4C  shows two universal box mounting adapters  20  mounted to a vertical kick bracket  19 . The vertical kick bracket  18  is secured with a wing  18  between two vertical studs  21  and a footer.  FIG. 4D  shows two universal box mounting adapters  20  secured to a horizontal kick bracket  19  and the horizontal kick bracket is secured to two vertical studs  21 . 
         [0040]      FIG. 5A-5B  show perspective views of a triple universal box mounting adapter  120  on a floor stand  150  and an extender  140  with a conduit hook  130 . The triple universal box mounting adapter  120  allows an installer to use a single plate for three junction boxes. The triple universal box mounting adapter  120  has similar features to the single universal box mounting adapter  20  previously described. This triple universal box mounting adapter  120  has side ears  121 , with vertical sides  122 , tabs  123  and top tab  124 . In these figures a conduit clip  130  is securable to the top tab  124 . The conduit clip  130  has multiple holes  131  with bendable tabs  132  that can be bend to retain conduit. 
         [0041]    The triple universal box mounting adapter  120  can be connected to an extender  140  by securing the extender  140  with tabs  125 ,  126  and  140 . A screw locks the parts together. The extender  140  is securable to the floor stand with tabs  141 ,  142 , and  154 . A bend  153  allows the front of the extender  140  and the floor stand  150  to be essentially parallel. While an extender  140  is shown, none or multiple extenders can be used. The bottom of the floor stand  150  has a bottom bend  152  and a hole to secure the floor stand  150  to a stud. 
         [0042]      FIG. 6A-6D  show perspective views installation of a triple or three universal box mounting adapter.  FIG. 6A  shows three universal box mounting adapters  20  mounted to a vertical stud  21  with a kick bracket  19 .  FIG. 6B  shows three universal box mounting adapters  20  secured to a vertical kick bracket  19  and the kick bracket  19  secured to a footer.  FIG. 6C  shows three universal box mounting adapters  20  mounted to a horizontal kick bracket  19 . The horizontal kick bracket  19  is secured between two vertical studs  21 .  FIG. 6D  shows a triple universal box mounting adapter  120  secured to an extender  140  on a floor stand  150 . The triple universal box mounting adapter  120  is shown secured between two studs  21 . 
         [0043]      FIG. 7  shows a perspective view of a four position universal box mounting adapter  129 . The four position universal box mounting adapter  129  allows an installer to use a single plate for four junction boxes. The quadruple universal box mounting adapter  129  has similar features to the single and triple universal box mounting adapters  20  and  120  respectively previously described. In this figure, the four position universal box mounting adapter  129  is shown mounted between two studs  21  secured to an extender  140  on a floor stand  150 . The floor stand  150  offers a height of 15″ when installed without the extender  140  and a height of 18″ with a single extender  140 . 
         [0044]      FIG. 8A-8E  show perspective views of different conduit supporting options on the securing tab  60 .  FIG. 8A  shows a flexible conduit  160  secured with tie wire  162  to the tab  60  and a rigid conduit  161  secured to the tab  60  with a one-hole strap  163  with a screw securing the one-hole strap to a hole in the securing tab  60 .  FIG. 8B  shows a rigid conduit  161  secured with the conduit clip  130 .  FIG. 8C  shows flexible conduit  160  secured with a Colorado Jim  164  conduit connector.  FIG. 8D  shows ridged conduit  161  secured to tab  60  using zip ties  165 .  FIG. 8E  shows a ridged conduit  161  secured to the tab  60  with Bat Wings clip  166 . 
         [0045]      FIG. 9  shows a perspective view of a universal box mounting adapter  20  installed on a metal stud  21  with secured flexible conduit  160  and rigid conduit  161 . The universal box mounting adapter  20  is shown with a front electrical box cover  172  and an electrical box  173  installed onto the universal box mounting adapter  20  where the front mounting flange  32  of the universal box mounting adapter  20  is secured to stud  21  and the other front mounting flange  31  is free. A conduit adapter  170  transitions from the rigid conduit  160  to the top of the junction box  173 . The ridged conduit  161  is secured with a one-hole strap  163  to the horizontal tab  60 . A conduit adapter  171  transitions from the flexible conduit  162  to the top of the junction box  173 . The flexible conduit  162  is secured with a tie wire  162  to the horizontal tab  60 . In this figure the central tab  50  is bent to provide a back support to the universal box mounting adapter  20 . 
         [0046]    Thus, specific embodiments of a universal box mounting adapter and system have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. 
       SEQUENCE LISTING 
       [0047]    Not Applicable.