Abstract:
An improved construction and method of constructing a field-bendable stud-engaging tab for electrical box supports that can be formed with less tool wear and bent in the field (for example, to conform to particular electrical box depths) with less force than previously required, and when necessary, straightened and re-bent. Scores are formed in the tab during the manufacturing process by applying shear force with a punch to the sheet metal of the tab, typically by a method in which the punch is applied to a portion of the sheet metal that rests over a cavity in the die, creating a sheared edge in each score wherein the metal is at least partially fractured, said fracture coinciding with at least part of a corresponding bend line. The bend lines also comprise unscored areas. In the field, the tab can be bent and re-bent along the bend lines.

Description:
FIELD OF INVENTION 
     This invention relates in general to an improved construction and method of constructing an electrical box support with a field-bendable stud-engaging tab that can be formed with less tool wear and bent in the field (for example, to conform to a particular electrical box depth) with less force than previously required, and when necessary, straightened and re-bent. 
     BACKGROUND OF THE INVENTION 
     U.S. Pat. Nos. 6,484,979 and 6,484,980 contain useful summaries of the prior art in the field of electrical box supports and the teachings of those patents as well as those referenced therein are incorporated by reference. From the prior art, it can be seen that numerous attempts have been made to find a more satisfactory bend line construction that provides a precise bend line and permits straightening and re-bending the tabs used in such products without risking breakage of the tab metal, but that heretofore no entirely satisfactory such product or associated method of manufacturing it has been achieved. 
     U.S. Pat. Nos. 6,484,979 and 6,484,980 represent an earlier attempt to solve some of the problems addressed by the present invention. They describe in a first embodiment two and in a second embodiment three struts that are assembled in telescoping relation to accommodate different stud spacing. A tab is provided on each of the outer ends of the support. Each line along which the tab can be bent, referred to as a bend line, is defined by a discontinuous score line in the shape of spaced-apart indentations formed in each bend line. These indentations, which only partially penetrate the thickness of the metal, are sufficiently deep to weaken the metal along the bend line to facilitate bending, straightening, and re-bending. These indentations are formed by plastic deformation of the steel as a result of application of a compressive force sufficient to deform the metal. This compressive force is applied by a male die containing V-shaped protrusions that is pressed down upon the sheet metal of the tab, which in turns rests upon a flat base. The pressure of the V-shaped protrusions upon the metal of the tab causes some of the metal to be displaced, thereby creating narrow depressions, or slotted indentations, in each location where a V-shaped protrusion contacted the metal of the tab. It has been discovered over time that although the method of forming indentations in the tab with a V-shaped protrusion, and the resulting tab, had many advantages over the then-existing prior art, nonetheless, the dies being referred to have a limited life span requiring substantial oversight and it would be desirable to further improve the life of the tool while maintaining and if possible improving upon the bend life of the tab in the field. Furthermore, it has been discovered that optimally according to prior practice, a compressive force of around five tons should be applied to appropriately form each indentation in the tab, thereby creating bend lines. By contrast, the present inventor has discovered that it would be desirable to form bend lines in such tabs using less force in order to simplify tooling requirements and extend the life of the tools. 
     From the foregoing description and the prior art references, it can be seen that numerous attempts have been made to find a more satisfactory bend line construction that permits bending, straightening, and re-bending without risking breakage of the tab metal prior to its final installation. Therefore, one object of the invention is to provide a further improved tab construction that, when used in connection with electrical box supports, can be applied to either a telescoping or non-telescoping type support, wherein the tab can be field bent along a well-defined bend line to accommodate boxes of different depths and when necessary, can be straightened and re-bent along the same or a different well-defined bend line without risk of breaking the metal forming the tab, and to accomplish this while maintaining a reasonably trouble-free work environment for the manufacture of the tab without continual oversight, maintenance, and tool replacement. An additional object is to design the tab and the method of making it so that less force need be applied to the die in order to create a bend line, and so that when the tab is made, a much longer tool life is achieved. A further object is to form a tab in such a way as to create indentations in the tab whose boundaries are at least partially sheared to facilitate ease of field bending. Other objects will become apparent as the description proceeds. 
     Prior to further describing the invention, some terms will be defined. The terms “box” and “electrical box” as used herein are intended to refer to a junction box, receptacle box, switch box, terminal box, connector box or the like as are known in the electrical trade. The term “stud” as used herein is intended to include any location to which an electrical box support can be mounted, which typically would be structural members in a building surface, including wall studs, joists, rafters, etc. The term “wall” as used herein is intended to include ceiling and floor surfaces as well as walls. 
     The word “score” when used with reference to the invention is used to refer to a depression, one or more of which are formed in each substantially flat metal tab by a punch and die during manufacture of a tab. The referred-to depression has a boundary, one section of which includes a substantially straight weakened and/or sheared edge (referred to hereafter as a “sheared edge”) and another section of which includes a substantially parallel edge (referred to hereafter as the “opposing shoulder”) opposite the sheared edge. As will hereafter be explained, the opposing shoulder may be less sharply defined than is the sheared edge, typically being bent, with a slightly rounded or sloping edge rather than a sharp edge. The term “score line” refers to a straight line along which the metal has been weakened and/or sheared. The above-referenced sheared edge of a score is an example of a score line. A “discontinuous score line” is a line composed of two or more aligned score lines separated by a section of metal that has not been weakened or sheared. One score includes one score line. Two scores in alignment with a non-weakened portion in between make up a “discontinuous score line.” 
     The term “bend line” refers both to a substantially straight line along which the tab has already been bent, and to such a line along which the tab could be bent if desired. The bend line coincides with at least one score line, which weakens the tab, thereby causing any bending forces applied to the tab to produce a bend in the weakened region along the score line. The bend line also includes at least one region that has no scores and that preferably has not otherwise been weakened, thereby giving such regions a degree of strength. A discontinous score line is a form of bend line. 
     The term “compressive force” refers to a force applied to at least one side of a tab so as to cause or tend to cause the two opposing sides of the tab to move closer to each other. The term “shear force” refers to a force applied so as to cause or tend to cause two adjacent parts of the same tab to slide relative to each other, in a direction generally parallel to their plane of contact or, stated differently, to slide in the direction parallel to the direction of travel of the applied force (since here, the force is applied to the tab from a uniform generally vertical direction). The term “plastic deformation” refers to deformation that is substantially permanent or nonrecoverable after release of the applied force. Other terms will be defined later as they arise in the description. 
     SUMMARY OF THE INVENTION 
     The improved electrical box support tab construction and method of the present invention is useful for both the telescoping as well as the non-telescoping type electrical box support formed of sheet metal and adapted to support an electrical box. The electrical box support has a tab on at least one end. Typically, such an electrical box support is intended to extend between a pair of wall studs and hence has a tab on each end. Each tab can be attached to a stud (or other structure) after being bent according to the specifications of the particular structure. The construction of these tabs, and the method by which they are constructed, distinguishes the present invention. 
     Each tab is made from a piece of substantially planar metal sheet joined to and typically integral with the electrical box support. The tab typically has at least one transverse bend line. Preferably, the tab has additional bend lines parallel to the first such bend line. The tab can be field bent along any one or more of these bend lines. The bend lines lie along at least one and, for a typically sized tab, preferably two score lines. Where more than one score is present on a score line, the scores are discontinuous, i.e. they are spaced apart. Where a score is present on a bend line that coincides with one or more notches in the tab, the score is spaced apart from each such notch. The position of the bend lines on the tab preferably coincides with positions at which a person installing an electrical box typically would be expected to bend the electrical box support in order to fit it around various boxes and studs having common dimensions and spacing. 
     Each score has a boundary defining its area. Each score penetrates the surface of the planar metal sheet along a major portion of the score&#39;s boundary. Along one portion of the score&#39;s boundary is a sheared edge. The sheared edge is substantially created by a shear force, wherein the shear force has caused that sheared edge to at least partially fracture, said fracture coinciding with at least part of the corresponding bend line or score line. That fracture weakens the tab, so that a bending force applied to a bend line that incorporates the score containing the sheared edge will cause the tab to bend along the sheared edge. This is how the location of the field bend is controlled in advance during manufacture of the tab. The score also has an opposing shoulder. The opposing shoulder has no fracture, and may not even penetrate the surface of the metal sheet. The score can also be looked at as a region of the planar metal sheet that has been at least partially weakened by the shear force applied to the sheared edge, thereby facilitating the tab being field bent along the weakened edge, which coincides with the bend line, and when necessary after being bent to be straightened and re-bent without further substantially fracturing the metal comprising the tab. It should be noted that part of the bend line is not along a score and hence remains unfractured by the manufacturing process, thereby maintaining the strength of the tab along the unfractured portion of the bend line. 
     As will be more particularly set out below, when the sheared edge is created, at least a portion of the metal that is deformed to create the sheared edge may be, but need not be, so fractured that it no longer is joined to that portion of the metal in the score that is connected to the opposing shoulder. If it is so fractured, the metal of the sheared edge may nonetheless touch or alternatively may be entirely disconnected from and not touch, the metal connected to the opposing shoulder. Compressive force applied by the punch in addition to the shear force may assist the separation of the sheared edge from the metal connected to the opposing shoulder. The same condition need not apply along the entire length of the sheared edge. That is, the metal of the sheared edge and the metal connected to the opposing shoulder may touch or be joined at some locations and not at others. 
     Another expression of the invention is to be found in a method for forming an electrical box support, of the type previously described, from a planar metal sheet. The support has a tab made of sheet metal on at least one end, and typically on two ends, each tab being designed to be attached to a stud. The electrical box support is made according to the prior art, for example as taught in U.S. Pat. No. 6,484,980, except with respect to the tabs which are constructed according to the invention as described herein. During manufacture, each tab is made with at least one transverse bend line intended to enable precise bending in the field. The tab can have more than one transverse bend line, and if there is more than one, the bend lines are parallel. Each bend line is characterized by the presence of one or more scores (as previously defined and described) along a discontinuous score line. 
     Shear force is applied to a tab in order to form each score, using a punch. The precision-formed point of each punch is straight at the back and diagonal on its front. The intersection of the front and back of the point preferably is chamfered. The chamfer can be so narrow in diameter as to be virtually non-existent, forming little more than a point at which the two flat surfaces meet, or it can be somewhat broader. Preferably it is a narrow edge but slightly wider than a point, to give it added strength when applied under force to the planar metal sheet as hereafter described. 
     In one aspect of the method of the invention, the shearing is carried out using a die beneath the punch with the planar metal sheet placed between the punch and the die, and with the punch capable of moving toward the die during the downward stroke of the punch far enough to enter the planar metal sheet but not far enough to emerge from the other side of the planar metal sheet. 
     In another aspect of the method of the invention, the die beneath the punch has a generally flat upper surface with a cavity in the upper surface beneath the punch, the cavity having at least one substantially straight edge. The substantially straight edge of the cavity is positioned parallel to and slightly apart from the straight back side of the point of the punch, so as to permit the planar metal sheet displaced downward by the downward stroke of the punch to enter the cavity of the die during the downward stroke of the punch. The straight edge of the cavity is placed close to the straight edge of the descending punch, but far enough away so that were the punch to descend beyond its normal range, it would pass closely by the straight edge of the cavity and down into the cavity without touching the die. Although a portion of the metal sheet is above the cavity as described, an adjoining portion of the metal sheet is supported by the die face adjacent the straight edge of the cavity, close to the entry point of the punch into the sheet, so that the descending punch creates a shear force on the metal sheet as one portion of the metal sheet continues to rest on the surface of the die while an adjacent portion of the metal sheet that formerly rested above the cavity is forced to slide downward, in a direction parallel to the force applied to the tab by the punch. 
     Other embodiments and aspects of the invention will be appreciated by persons skilled in the art from the drawings and further description and claims herein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective illustration of a first embodiment of an electrical box support embodying the inventive tabs, made up of two releasably engaged struts and showing the front surfaces of the inventive tabs at the ends thereof, before the tabs have been bent in the field for attachment to adjacent wall studs and to accommodate to a particular depth of electrical box. 
         FIG. 2  is a perspective illustration of the adjustable electrical box support embodying the inventive tabs as shown in  FIG. 1  after the tabs have been bent to accommodate a particular depth of box and in a form suitable to being attached to a pair of spaced apart wall studs. 
         FIG. 3  is a perspective illustration of the adjustable electrical box support embodying the inventive tabs as shown in  FIG. 1  after being attached to a pair of adjacent wall studs with an electrical box of a particular depth mounted thereto. 
         FIG. 4  shows a side view of the punch and die assembly used to form the inventive tabs, with a tab placed therein. 
         FIG. 5  is a section view of a portion of the punch and die assembly with a tab placed therein, taken in the direction of line  5 - 5  of  FIG. 4 . 
         FIG. 6  is an enlarged fragmentary view of a side elevation of a portion of the punch and die assembly with a tab placed therein, taken immediately after the punch has made its full descent and is partially raised. 
         FIG. 7  is an enlarged fragmentary side view of the tab shown in  FIG. 6 , above a plan view of a section of that tab, with dashed lines from the side view to the plan view showing the relative position of certain elements of the score in both views. 
         FIG. 8  is a perspective view of the back of the punch used to form the inventive tabs. 
         FIG. 9  is a perspective view of the front of the punch used to form the inventive tabs. 
         FIG. 10  is a side view of the punch used to form the inventive tabs. 
         FIG. 11  is a close-up perspective side view of a portion of the punch used to form the inventive tabs. 
         FIG. 12  is a top plan view of a tab with two bend lines and four scores. 
         FIG. 13  shows an enlarged fragmentary portion of the right end of the electrical box support of  FIG. 1 , including tab  18 , to illustrate the scores shown in greater detail. 
         FIG. 14  shows a tab punched in an alternate configuration from that shown in  FIG. 12 . 
         FIG. 15  shows an alternate configuration of the punch and die assembly, used to punch the tab shown in  FIG. 14 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The inventive tabs are described with reference to their use on electrical box supports. In reference to  FIG. 1 , adjustable electrical box support  10  is illustrated as comprising inner strut  12  and outer strut  14 . Inner strut  12  and outer strut  14  are formed as elongate channels that are sized to telescopically nest. Inner strut  12  slidingly resides within outer strut  14  to allow a user to telescopically adjust the overall support length X shown in  FIG. 1 . Inner strut  12  and outer strut  14  of support  10  are preferably formed with a channel-shaped cross section to provide stiffness and maintain secure engagement of the mating struts. Inner strut  12  and outer strut  14  are preferably formed of galvanized sheet steel, as is known in the electrical trade, of appropriate gauge and of channel dimensions to provide sufficiently stiff support for securely mounting one or more electrical boxes or other devices thereon. For example, 24-gauge (0.6 mm; 0.025 inch thick) sheet steel has been found to be a satisfactory material for the struts including the inventive tabs hereafter described. 
     Inner strut  12  terminates with tab  18  that essentially is an extension of web  12   f . A pair of notches or cuts  16  are formed on opposite edges of tab  18  at its juncture to the inner strut web  12   f . These notches or cuts  16  can be conventional minimal notches or cuts to provide stress relief during the cutting and bending operation. They may also guide bending of the tab, as shown in  FIG. 1 . A bend line  22  preferably comprising one score  20  and two notches  16 , here shown as comprising two scores  20  and two notches  16  (one of which is not seen in this view), is formed in the surface of tab  18  substantially perpendicular to axis L of inner strut  12  and axis L′ of outer strut  14 . As can be seen, notch  16  is formed with straight edges, two of which terminate at a point substantially coincident with a terminus of bend line  22 , to guide the bending of tab  18  along bend line  22 . A bend line  22   a  comprising a pair of scores  20 ,  20  is formed in the surface of tab  18  substantially perpendicular to axis L of inner strut  12  and axis L′ of outer strut  14 , and at selected distances D, D′ from notches  16 , leaving some additional length of tab  18  extending beyond. Tab  18  can be bent along these bend lines, preferably to form a right angle at the bend line. 
     Distance D is preferably determined to allow a standard 1½-inch (38-mm) deep electrical box, when mounted to support  10  and extending outwardly therefrom, to be flush with the inner surface of a wall subsequently assembled to the wall studs S and S′ ( FIG. 3 ). Distance D′ is located similarly for a standard electrical box that is 2⅛ inches (54 mm) deep. In other words, distance D or distance D′ is substantially equal to the depth of the electrical box being mounted. 
     Outer strut  14  has tab  26  that essentially is an extension of web  14   f , with notches  24 , similar to the previously described notches  16 , and scores  28 ,  28 , to facilitate bending of tab  26  at a right angle as described above in relation to tab  18  of inner strut  12 . Bend line  23  illustrates two notches  24 , formed as described with respect to notches  16 , to guide the bending of tab  26  along bend line  23 . It has been discovered that such notches are particularly useful for guiding bending when only one score is present on a bend line. 
     In the interest of improving the efficiency of field installation, end tabs  18 ,  26  may be preformed (not shown) at a right angle to the length of electrical box support  10  at the factory and shipped in this form. When this is done, the installer only has to make a single bend at each end, so that the end of the tab can bend around and be affixed to an adjacent stud, thus cutting the required number of bends for this field-bending operation in half. 
       FIG. 2  shows support  10  after tab  18  and tab  26  have each been bent to form a pair of sequential right angles for installation between a pair of adjacent studs. According to the present invention, tab  18 , by way of example, is bent at bend line  22  in a first bend direction and at bend line  22   a  in a second bend direction. After bending tabs  18  and  26 , the assembled inner strut  12  and outer strut  14  are telescoped to adjust length X of support  10  in the direction shown by arrow A to fit the stud separation distance required. 
     Referring now to  FIG. 3 , electrical box support  10  is shown after it has been adjusted in length and fixedly attached by means of fasteners F to adjacent studs S and S′, with detents  32  and  34  releasably locking the support length X during attachment. As noted above, length X of support  10 , when assembled, is substantially equal to the spacing between adjacent studs S, S′. Tabs  18  and  26  may be pre-punched with holes  19  to accept fasteners F (as illustrated in  FIGS. 1 ,  2 , and  3 ) or the needed holes may be formed during installation. 
     To supplement what has been previously stated with regard to the scores  20  ( FIG. 1 ), it has been found through further experimentation that when the struts  12  and  14  are made of 24 gauge sheet steel (0.6 mm; 0.025 inch thick) and the tabs, i.e. tab  18  and  26 , are 1¾ inches in width and scores  20 ,  28  are each 7/16 inch long with a totally fractured sheared edge, tabs  18 ,  26  can be repeatedly straightened and re-bent, typically up to at least eight times without tab metal breakage. This is of course an extremely important advantage in the field where it is often necessary for reasons previously described to straighten and re-bend a tab after having been bent on a different bend line. Such bending, straightening, and re-bending may in fact have to be repeated several times because of particular field conditions, but many of the prior art methods produce a tab with bend lines defined by spaced apart holes or slots in which the metal rapidly fractures when repeatedly bent along the bend lines and hence breaks in the field during the bending process prior to installation. Another advantage to be found when scores  20 ,  28  are formed in the manner described, is that when bent and even after being straightened and re-bent, the tab bend lines of the invention permit the tab to have a so-called square bend, i.e. a relatively sharp 90-degree angle. 
     In  FIG. 4  and  FIG. 5 , side and end views, respectively, are shown of a punch and die assembly for forming scores  20  ( FIG. 1 ), in the tab  18 . Each punch  70  is composed of at least one punch head, and preferably two such punch heads  70   a ,  70   b  mounted on a punch base  70   c . In  FIG. 4 , punch  70  is shown with its base  70   c  mounted, at the side opposite that on which the punch heads  70   a ,  70   b  are attached, to the bottom surface of press support  73  and actuated by a press drive  74 . Other means of driving a punch are understood in the art and could be applied to the invention. 
     The details of the punch portion of the assembly are best shown in  FIGS. 8 ,  9 ,  10  and  11 . Perspective views of the back and front of the punch  70  are provided respectively in  FIGS. 8 and 9 . A side view of punch  70  is provided in  FIG. 10 , and  FIG. 11  provides a perspective side view of a portion of punch  70 , focusing on the punch heads  70   a ,  70   b.    
     Each punch head  70   a ,  70   b  is provided with a punch head shaft  71  joined to a punch head point  72 . In  FIG. 9  and  FIG. 11 , punch head shaft  71  and punch head point  72  are shown with respect to punch head  70   a , and the location of the juncture between the punch head shaft  71  and the punch head point  72  is indicated by a dashed line. The punch head shaft  71  is in the shape of a rectangular box, a back face of which can be seen in  FIG. 8 , a front face of which can be seen in  FIG. 9 , a side face of which can be seen in  FIG. 10 , and a side face and a portion of the back face of which can be seen in  FIG. 11 . The punch head point  72  is in the general shape of a right triangular prism, the front face of which can be seen in  FIG. 9 , a side face of which can be seen in  FIG. 10 , and a side face and the front face of which can be seen in  FIG. 11 . The bottom face of the punch head point  72  is flat, is rectangular in shape, and is equal in size to the punch head shaft  71  to which it is joined, although persons skilled in the art will appreciate that variations in the shape and size of the punch head shaft  71  and/or punch head point  72  can be made in keeping with the teachings of the invention, in which case the bottom face of the punch head point  72  may not be equal in size or shape to the punch head shaft  71  to which it is joined. The back  78  and front  79  faces of the punch head point are each flat, rectangular in shape, and equal in width to the width of the punch head shaft as shown respectively in  FIG. 8  and  FIG. 9 . The two side faces of the punch head point  72  preferably are flat, and are triangular in shape, as shown with respect to one such side face in  FIG. 11 . Preferably the punch head shaft  71  is relatively short in height, approximately equal to the height of the punch head point  72  (as shown in  FIG. 11 ). Alternatively, the shaft could be longer or shorter, or a shaft of reduced diameter in at least one dimension as compared to the point could be used. The intersection of the back face  78  and front face  79  of the punch head point preferably is chamfered to form a narrow, straight bottom edge hereafter referred to as the chamfer  80 , to reduce cutting-edge chipping at the point. Preferably, at least each punch head is a single integral structure, and the entire punch  70  including the punch heads  70   a ,  70   b  and punch base  70   c  may be an integral structure as shown in  FIG. 9 . 
     As shown in  FIG. 4 , Punch  70  is positioned above a flat die  75 . The die  75  preferably rests on a die holder  76 . The die  75  has a cavity  77  ( FIG. 5 , and also shown with dashed lines in  FIG. 4  and, in an enlarged view, in  FIG. 15 ) directly beneath each of the punch heads  70   a ,  70   b . The shape of cavity  77  is roughly the same as the shape of punch shaft  71  but can be any shape appropriate to serve the function described herein, and the cavity  77  is large enough to permit entry of punch point  72  and of displaced material  92  ( FIG. 6 ) from tab  18 , as hereafter described. These cavities  77  each penetrate the die face  85  ( FIG. 6 ) of die  75  and extend at least partially through the body of die  75 . Each cavity  77  presents a straight edge  84  ( FIG. 6 ) parallel to, and slightly offset from, the back face  78  of the corresponding punch head. The offset is such that if the punch head point  72  were to descend lower than the die face  85  of the die  75 , the punch would enter the cavity without touching the die. The punch  70  and die  75  are formed of hardened steel. The depth of the press stroke is limited by precision stops  86 ,  88 , which precisely limit the travel of punch  70  so as to permit the punch heads to enter the metal sheet of tab  18  but not to emerge from the other side. The depth to which the punch heads  70   a ,  70   b  can travel is indicated in  FIG. 4  by dashed line  73  and their travel is shown as limited such that it ends at a point higher than the bottom of cavities  77 . 
     Referring now to  FIG. 6 , part of the process for making a score in a tab is shown.  FIG. 6  shows an enlarged fragmentary view of a side elevation of the punch and die assembly with a tab  18  placed therein, taken immediately after the punch  70  (the punch head shaft  71  and punch head point  72  of which are shown in  FIG. 6 ) has made its full descent and is partially raised. The punch  70  is shown in  FIG. 6  as having descended into the surface of the metal sheet of tab  18  but not descended far enough to emerge from the bottom of the tab. The front face  78  of the punch head point  72  is shown aligned just to one side of the edge  84  of the die cavity  77 . The figure shows a cross section of a portion of the punch  70 , the die  75 , and a tab  18  placed on the die. The back face  78  as well as the front face  79  of the punch head point  72  can be seen, as well as the chamfer  80  between those front and back faces. The die  75  is shown in vertical cross section through die cavity  77 . Edge  84  of the die cavity  77 , together with the adjoining portion of die face  85 , can be seen supporting the tab  18  beside the entry-point of the punch head point  72  into the tab  18 . Also visible in  FIG. 6  is the displaced material  92  from the tab  18  extending down into the die cavity  77 . The sheared edge  94  of that displaced material  92  is shown separated from the sheared edge  90  of the tab  18 , although in some constructions of the invention the sheared edge  94  of displaced material  92  is not fully separated from the sheared edge  90  of the tab  18 . Sheared edge  90  forms the sheared edge of a score  20  (see  FIG. 7 ) that has been produced by the action of the punch  70  against the metal sheet of the tab  18 . As can be seen in  FIG. 6 , opposing shoulder  96 , which forms a boundary of the score opposite to that formed by sheared edge  90 , is not depicted as a sharp edge and typically will not be a sharp edge. The sheared edges  90 ,  94  are substantially produced by shear force as a result of the punch head  70   a , and particularly the back face  78  of the punch head point  72 , being forced against the metal of tab  18  as it enters cavity  77  parallel to edge  84 , thus causing the metal of sheared edge  94  to slide relative to the metal of sheared edge  90 , in a direction generally parallel to the direction of travel of back face  78 . 
       FIG. 7  illustrates the relationship of the enlarged fragmentary view of  FIG. 6  to a plan view of a score  20  in a tab  18 .  FIG. 7  repeats the sectional view of tab  18  from  FIG. 6 , but without showing the punch and die that formed a score therein.  FIG. 7  also shows a plan view of tab  18  as viewed from above the tab, showing the location of score  20  thereon. Elements forming score  20  are connected by dashed lines from their illustration in the sectional view at the top of  FIG. 7  to their illustration in the plan view at the bottom of  FIG. 7 , to show their orientation and relative positions. In particular, sheared edge  90  is shown in cross-section and then in plan view, with a dashed line connecting the two illustrations of that element. Opposing shoulder  96  is shown in cross-section and in plan view, again with a dashed line connecting the two elements. Sheared edge  94  is shown in cross-section and in plan view, with a dashed line showing the position of the lower edge of sheared edge  94  in cross section and in plan view. It should be noted that sheared edge  94  of the displaced material from the tab  18  is shown separated from the sheared edge  90  of the tab  18 , although in other embodiments the two edges are not separated or are only partially separated. 
     In  FIG. 12 , a tab  18  is shown with two bend lines  98 , each bend line with two scores  20 . The sheared edge  90  of the score as well as the opposing shoulder  96  of the score are shown. 
     More detail of the scores  20  of  FIG. 12  is shown in  FIG. 13 . The sheared edge  90  and the opposing shoulder  96  are both shown. As explained above, the boundary of each score  20  includes the sheared edge  90  and the opposing shoulder  96 . 
     Various embodiments of the punch assembly used to carry out the method of the invention have one, two, or more punch heads. In some embodiments having more than one punch head, the orientation of each punch head is the same, as shown in  FIG. 4 . But alternatively, each punch head can be oriented in a direction opposite to that of one or more adjacent punch heads.  FIG. 14  depicts the scores  20  produced when such an alternate punch configuration, depicted in  FIG. 15 , is used, and the position of those scores  20  with respect to the bend line  98 . For each bend line  98 , the opposing shoulders  96 ,  96  of the scores  20  that help define the bend line fall on opposite sides of that bend line. This is in contrast to the scores shown in  FIG. 12 , where for each bend line  98 , the opposing shoulders  96 ,  96  fall on the same side of that bend line. 
       FIG. 15  illustrates the alternative punch embodiment used to produce the scores shown in  FIG. 14 , in which the punch heads of punch  70  are oriented so that the front face  79  of one punch head point and the back face  78  of an adjacent punch head point each face the front of the punch  70 . When the punch assembly containing these two oppositely oriented punch heads is used, it creates a score pair that is symmetrical about the bend line. 
     In summary, the following are among the advantages of the sheared score bend line tab construction of the invention employed on electrical box supports used for field installation of electrical boxes: 
     1. Tabs can be bent, straightened and re-bent without the risk of premature breaking of the metal forming the tab. 
     2. The bend line made up of one or more scores provides a sufficiently precise point of bend to ensure that the outlet box (once installed) will rest in a plane parallel to the sheetrock. 
     3. There is a minimum radius at the point of the bend, allowing the tabs to nest snugly against the studs. 
     4. The centerline of the bend is substantially uniform with respect to the discontinuous score line. 
     5. The mounting tabs, i.e. that portion of the tabs remaining at the end after bending and used to mount the tab to the stub, will always be substantially the same length, as there is virtually no variation in the bend line. 
     6. Unlike scores made with perforations intended to facilitate field punching out of scores along selected bend lines, metal does not have to be removed to establish the point of bend. 
     7. Maximum strength and rigidity to the electrical box support&#39;s mounting tabs is achieved while retaining a substantial portion of the metal&#39;s resiliency to withstand multiple bend cycles without fractures. 
     8. The die used to form the score lines is not subject to chipping or damage even after repeated use. 
     9. The force required to operate the punch in the shearing fashion of the invention is much less than the five tons of force needed to operate the die of the prior art to form each indentation in the tab in a compressing fashion. Less than 1000 pounds of pressure is required to operate the punch of the invention to form each indentation, and the punch can be effectively operated with less than 300 pounds of force. This reduction in force leads to longer tool life and much simpler operation of the manufacturing equipment. 
     The above description of embodiments of the invention is provided by way of example and not as a limitation. Accordingly, various modifications and variations obvious to a person of ordinary skill in the art to which it pertains are deemed to lie within the scope and spirit of the invention as set forth in the following claims.