Mounting block

An integral electrical component mounting block comprising a central electrical box having a generally closed bottom, an open top, an interior volume and a top periphery, a planar medallion portion about the top periphery of the electrical box, the planar medallion having an outer periphery, a flange about the outer periphery extending in the direction of the electrical box to a depth about equal to that of the electrical box. The closed bottom of the electrical box includes a centrally located mounting hole, at least one means for access of power cable and a pair of slots or otherwise adjustable channels extending into the volume of the electrical box for receipt of and passage therethrough of mounting bolts for an electrical device attached through the mounting block.

FIELD OF THE INVENTION 
The present invention relates to electrical device mounting assemblies and 
methods for their installation, and more particularly to a mounting 
assembly or block for ceiling fans, light fixtures and the like that 
require stable, heavy duty mounting structures. 
BACKGROUND OF THE INVENTION 
Mounting structures for electrical devices have met increasing demands for 
strength and stability with the advent and common installation of ceiling 
fans, particularly lighted such devices, large chandeliers and large 
exterior sconces. While each of these electrical fixtures or devices has 
its own unique set of mounting problems, ceiling fans with their large 
heavy motors and often the addition of lighting devices, have posed a 
particular issue because of the large static loads which they represent 
when hung from a ceiling. Additionally, the fan rotation provides a 
dynamic load that also requires consideration when mounting such devices. 
There have been numerous efforts in the prior art to provide adequate 
structure for the hanging or mounting of large electrical devices that 
represent large static and/or dynamic loads. 
U.S. Pat. No. 4,892,211 To Jorgensen describes a ceiling box for mounting 
and supporting a ceiling fan on a ceiling. The ceiling box includes a top 
wall portion with a side wall portion surrounding the periphery of the top 
wall portion. The box is open at the end opposite the top wall portion and 
the side wall portion has a pair of flanges extending normal thereto into 
the open end of the box. These flanges have holes in them for receiving 
fan-supporting screws. In a first embodiment, a pair of threaded mounting 
screw holes are formed in the top wall portion and are each axially 
aligned with an unthreaded hole that extends through the respective 
flange. In a second embodiment, the holes in the flanges are also threaded 
for added support. 
U.S. Pat. No. 5,183,233 to LaPalomento, describes a support for hanging an 
electrical fixture from a ceiling or wall and a method for suspending the 
fixture. The sup [port comprises a panel that is intended to be affixed to 
the grid work of a house and a support affixed to the panel that holds the 
electrical fixture. A slot is provided on the rear of the panel to hold 
the panel flush against a flat surface and to allow electrical wiring to 
connect to the electrical fixture. 
U.S. Pat. No. 5,234,119 to Jorgensen et al, describes a plastic ceiling box 
adapted to support a ceiling fan and designed to be mounted on a 
structural member, such as a ceiling joist. The ceiling box comprises a 
body member having a lower wall and a pair of sidewalls defining a recess 
for snugly receiving a ceiling joist. Box mounting holes for receiving box 
mounting fasteners are located at opposite sides and ends of the lower 
wall for attaching the ceiling box to the joist. Openings for receiving 
fan supporting fasteners are formed in the body member adjacent the box 
member and aid in attaching the body member to the joist. This overall 
arrangement provides sufficient support and strength to resist dynamic 
loads imposed by the ceiling fan even though the ceiling box is made of 
plastic. 
U.S. Pat. No. 5,522,577 to Roesch describes a mounting assembly for 
supporting a ceiling fan that includes a sup [port beam located inwardly 
of the ceiling surface a predetermined distance. An electrical box having 
a bottom wall is directly joined to and supported from the support beam. 
The box has sidewalls extending from the bottom wall through the ceiling 
substantially to the exposed ceiling surface and terminating in an open 
end. A rigid metal plate or disk member adapted for supporting and 
mounting a ceiling fan is positioned over the open end of the box. The 
disk member is of a size sufficient to have a peripheral portion extending 
radially beyond the side walls of the box and a plurality of mounting 
screws extend from the metal disk member through the interior of the box 
into connected engagement with the beam. The mounting screws support the 
disk member from the beam without reliance on the electrical box for 
support. 
U.S. patent application Ser. No. 08/927,614 entitled "Ceiling Medallion 
Assembly" filed Sep. 11, 1997 in the name of Thomas J. Gretz describes a 
mounting assembly for holding an electrical device in place on a joist or 
stud. The assembly includes an electrical box having a planar base, 
preferably with three planar surfaces of different depths, a fastener 
device for temporarily securing an electrical box in place, a ceiling 
medallion for covering the electrical box, a second fastener device for 
temporarily securing the ceiling medallion to the electrical box and a 
fixation device for securely fastening the electrical box and a ceiling 
bezel to the joist or stud. The electrical box for mounting on the joist 
or stud includes: a generally rectangular housing with two opposite sides 
having a stepped appearance defining three different depths of the housing 
with a third side at a first shallow depth and a fourth side at a third 
deepest depth, a first back piece spanning the opposing sides at a first 
depth approximately equal to the thickness of the ceiling material, a 
second back piece spanning the opposites sides of the second depth that is 
greater than the first depth of the first back piece, the second depth 
being approximately equal to twice the thickness of the ceiling material 
and a third back piece spanning the opposite sides at a third depth that 
is greater than the second depth of the second back piece. 
Although the foregoing methods and apparatus have all attempted to solve 
the problem of adequately mounting the increased loads of electrical 
fixtures, none have provided a simple yet universal solution that can be 
used in either a new or existing installation that may or may not have or 
be capable of being provided with an electrical junction box proximate a 
joist or stud without creating a rather large and/or unsightly hole which 
then must be covered with an appropriate medallion or otherwise, but which 
poses a significant repair, if the electrical device is subsequently 
removed. 
SUMMARY OF THE INVENTION 
According to the present invention, there is provided a universal yet 
simple mounting block for mounting electrical devices such as ceiling 
fans, chandeliers, wall sconces, etc. that produce large static and/or 
dynamic loads. The mounting block of the present invention is easy to 
install, is mounted external to the mounting surface and relies on the 
structural members of the building to which the device is being attached 
to provide the strength required to carry the elevated weight and load. 
Additionally, no preexisting electrical box or the creation of a large 
hole to accommodate such an electrical box is necessary with the mounting 
block of the present invention. 
The mounting block of the present invention is an integral component 
comprising a central electrical box having a generally closed bottom, an 
open top, and a top periphery, a planar medallion portion about the top 
periphery of the electrical box, the planar medallion portion having an 
outer periphery, a flange about the outer periphery of the medallion 
portion extending in the direction of the electrical box and of a depth 
generally equal to or slightly greater than the depth of the electrical 
box. The closed bottom of the electrical box includes a centrally located 
mounting hole, at least one knock-out for access of power cable and a pair 
of slots or otherwise adjustable channels extending into the volume of the 
electrical box for receipt of and passage therethrough of mounting bolts 
for the electrical device to be attached to a structural member through 
the mounting block. A method for the installation of an electrical device 
using such a mounting block is also described.

DETAILED DESCRIPTION 
As shown in FIG. 1, the mounting block 10 of the present invention 
comprises an electrical box 12 having a generally closed bottom 14, an 
open top 16, and a periphery 18 about open top 16. About periphery 18 and 
integrally formed with electrical box 12 is medallion portion 20. About 
the distal periphery of medallion portion 20 is a flange 22. As seen most 
clearly in FIG. 2, flange 22 is generally of the same depth as electrical 
box 12 so that when mounting block 10 is installed as described 
hereinafter, flange 22 and the rearmost surface 24 of electrical box 12 
both contact surface 23, to which mounting block 10 is being attached, 
simultaneously to form a neat junction between flange 22 and surface 23. 
Flange 22 may extend perpendicular to planar medallion portion 20, or, as 
shown in FIGS. 1 and 2, be tiered or otherwise ornamental in design to 
provide a smoother and more aesthetically pleasing transition. Medallion 
20 may of course be of any suitable diameter or shape and may be varied 
depending upon the size and/or shape of the base of the electrical device 
being installed thereover. Similarly, although electrical box 12 is shown 
as being round, it could be square or any other shape so long as it is 
covered by the base of the fixture to be installed. 
Bottom 14 of electrical box 12 includes a centrally located hole 26 for 
attachment of mounting block 10 to a suitable structural member such as a 
joist or stud using a screw during installation, and at least one and 
preferably a pair or more of knock-outs 28 for access of appropriate cable 
to interior volume 29 of electrical box 12. Extending into the interior 
volume 29 of electrical box 12 are two slots 30 or otherwise adjustable 
members for receipt of electrical device mounting screws 32 as described 
hereinafter and shown in FIG. 2. It is preferred that slots 30 be of the 
same general depth as electrical box 12 and flange 22 for reasons 
described hereinafter. It is also preferred, as shown in FIGS. 1 and 2, 
that hole 26 be countersunk in bottom 14 of electrical box 12 such that 
hole 26 has a peripheral wall 27 that aligns an inserted screw 36 when 
installed as described below. 
As shown in FIG. 2, installation of mounting block 10 of the present 
invention is accomplished by first locating a structural member 34, 
generally a stud or a joist, in the area where the electrical device is to 
be mounted, and drilling an appropriately sized hole, for example a 1/2" 
hole, 35 through ceiling or wall material 37 and into structural member 
34. Whatever appropriate number of knock-outs 28 are then punched out of 
bottom 14 of electrical box 12 and a hole or holes of suitable size for 
the passage of cable through wall or ceiling material 37 drilled therein 
with slots 30 and hole 26 aligned with structural member 34. Mounting 
block 10 is then attached to structural member 34 by insertion of screw 36 
or other appropriate fastener, e.g. a nail, through hole 26 in mounting 
block 10, appropriate cable passage hole or holes (not shown) aligned with 
the apertures formed by removal of knock-out(s) 28 and insertion of cable 
retainer 42, shown in FIG. 4, and slots 30 aligned with structural member 
34 before tightening of screw 36. Since screw 36 will bear little or no 
weight when the installation is finalized, as described hereinafter, a #8 
11/2" wood screw, for example, is adequate in most cases to temporarily 
fasten mounting block 10 into place while installation proceeds. 
Electrical fixture or fan mounting bar 38 that is provided with the 
electrical fixture or fan 40, is then attached over mounting block 10 by 
insertion of appropriate larger sized screws 32 through mounting bar 38 
and slots 30 so that screws 32 are securely fastened into structural 
member 34. Since screws 32 are going to bear the entire weight of 
electrical device 40 in the final installation, it is important that they 
be of adequate size and strength to support the static and/or dynamic load 
imposed by electrical device 40. In most instances, two 3"#10 wood screws 
will be adequate for the purpose; however, care should be taken that 
screws 32 are of adequate size and strength to support electrical device 
40. It is preferred that lock washers 46 be installed on screws 32 to 
prevent loosening of screws 32, particularly in a dynamic load situation 
of the type encountered with ceiling fans installations. Once mounting bar 
38 is properly installed, electrical device 40 is attached thereto in 
accordance with normal installation practice as directed by the 
manufacturer of electrical device 40. 
During this stage of the installation, the necessary electrical cable(s) 
are secured in the apertures left by removal of knock-out(s) 28 by 
insertion through a cable retainer 44 of the type shown in FIG. 4 which 
is, in turn, inserted into the apertures left by the removal of knock-outs 
28. 
While slots 30 are shown in the drawings as the recipients of screws 32, it 
should be clear that other suitable arrangements of adjustable apertures 
which permit receipt of screws 32 and passage therethrough for fastening 
to structural member 34 are also contemplated. It is also preferred that 
slots 30 be of the same depth as that of electrical box 12 such that 
attachment of mounting bar 38 as described hereinabove with screws 32 
results in an intimate and compressive and therefore rigid joining of 
mounting bar 38, mounting block 10, ceiling or wall material 37 and 
structural member 34. 
In view of the integral character of mounting block of the present 
invention, it is preferred that it be manufactured from a plastic or 
polymeric material having adequate insulating characteristics. Injection 
molding is the preferred mode of manufacture. 
From the foregoing description, one skilled in the art can easily ascertain 
the essential characteristics of this invention, and without departing 
from the spirit and scope thereof, make various changes and modifications 
of the invention to adapt it to various usages and conditions. It is 
therefor intended that the scope of the invention be limited only by the 
scope of the appended claims.