Mounting plate and cover assembly for electrical devices

Combination mounting plate and cover assemblies for mounting an electrical outlet box on one side of a stud in a wall are provided. The mounting plate and cover assemblies are configured to receive an additional bracket and/or outlet box on an opposite side of the stud. The combination mounting plate and cover assemblies can be single unitary members serving the multiple functions of a raised cover ring, a box support, and a secondary bracket/outlet box support. Systems including combination mounting plate and cover assemblies having an electrical box and a bracket or second outlet box attached thereto.

TECHNICAL FIELD

The invention relates generally to combination mounting plate and cover assemblies for mounting an electrical outlet box to a stud.

BACKGROUND

Outlet box mounting assemblies are used to secure an electrical outlet box to a stud in a wall. Typically, an electrical outlet box is attached to a mounting assembly that is further attached to a wall stud. However, certain conventional mounting assemblies do not firmly secure to the stud, and in turn, cause undesired deflection, or movement in the direction perpendicular to the wall, of the attached electrical outlet box upon force, such as from a plug being inserted into the outlet box. Accordingly, such mounting assemblies require an auxiliary member, such as a stiffening arm, to reduce undesired deflection of the outlet box when attached to the wall stud.

Additionally, most conventional mounting assemblies require two separate components: an outlet box support and a raised cover ring. The outlet box and mounting assembly components must be assembled and connected in sequence, which is labor intensive. While some existing combination mounting plate and cover assemblies having a reduced number of components are able to mount an outlet box on a stud such that some movement of the outlet box is prevented, these assemblies do not allow mounting of additional brackets or brackets and outlet boxes on the opposite side of the stud.

Therefore, a need exists in the art for an outlet box mounting assembly that can firmly secure to a stud, has a reduced number of components for assembly, accommodates a main electrical outlet box, and can accommodate mounting of an additional bracket and/or outlet box.

SUMMARY

The present invention can satisfy the above-described need by providing a combination mounting plate and cover assembly for mounting an electrical outlet box to a stud in a wall such that the electrical outlet box may substantially prevented from moving in any direction. The combination mounting plate and cover assembly also is configured to receive an additional bracket or outlet box on the opposite side of the stud. Generally, the combination mounting plate and cover assemblies of the present invention are single unitary members serving the multiple functions of a raised cover ring, a box support, and a secondary bracket/outlet box support.

According to one exemplary aspect, the combination mounting plate and cover assemblies of the present invention include a single unitary member having a first edge, a second edge, an open portion for receiving an electrical outlet box, and a planar portion extending laterally from the open portion to the second edge. The open portion is positioned closer to the first edge than to the second edge. Typically, a raised rib is formed about the circumference of the open portion. The combination mounting plate and cover assembly comprises multiple openings for securing an electrical outlet box to the single unitary member. The openings are positioned proximate the open portion, disposed between the open portion and the first edge and between the open portion and the second edge. The planar portion comprises holes for securing the single unitary member to a stud, as well as apertures for securing the single unitary member to a bracket or second electrical outlet box on a side of the stud opposite to the other electrical outlet box. The apertures are proximate the second edge, and the holes are positioned between the second edge and the open portion. In certain exemplary aspects, the assembly also may comprise a far side support extending orthogonal to the first edge. In some exemplary aspects, a leg may extend from the planar portion for additional support against a side wall of the stud. In some exemplary aspects, the planar portion may include a viewing window to find markings in the stud.

A system according to an exemplary aspect of the present invention comprises combination mounting plate and cover assemblies having an electrical outlet box secured thereto at the open portion proximate to the first edge of the assembly and having a bracket or second electrical outlet box secured thereto at the planar portion proximate to the second edge of the assembly. The system can be mounted to a stud in a wall via holes in the planar portion.

Combination mounting plate and cover assemblies of the present invention may reduce or eliminate undesired movement of the electrical outlet box and assembly while using a reduced number of components compared to conventional mounting assemblies. Combination assemblies according to the invention also can allow a user to mount a bracket or second outlet box to the assembly, which is not possible with conventional combination assemblies.

These and other aspects, objects, and features of the invention will become apparent to those having ordinary skill in the art upon consideration of the following detailed description of exemplary embodiments exemplifying the best mode for carrying out the invention as presently perceived.

DETAILED DESCRIPTION

The present invention may be better understood by reading the following description of non-limitative embodiments with reference to the attached drawings wherein like parts of each of the several figures are identified by the same reference characters.

Referring toFIG. 1, an exemplary combination mounting plate and cover assembly100is illustrated as a single unitary member. Assembly100may be fabricated from any suitably rigid material. In exemplary embodiments, suitable rigid materials include, but are not limited to, sheet metal and plastic. Assembly100may have a thickness equal to or greater than about ⅛ inch.

In certain embodiments, assembly100may be generally rectangular with a first side edge102and an opposite, second side edge104. Multiple spaced-apart openings (or slots)106a,106bare included in assembly100. Openings106a,106bmay be elongated for adjustable connection of an electrical outlet box (such as a junction box or other suitable box) (not shown) to assembly100. In certain exemplary embodiments, four openings may be included, two openings106abeing proximate first side edge102for connection to one side of the electrical outlet box and two openings106bpositioned on assembly100for connection to the opposite side of the electrical outlet box.

The portion of assembly100between openings106band the second side edge104is defined as a planar portion108. Planar portion108comprises at least two spaced-apart holes110between second side edge104and openings106b,wherein holes110are spaced a short distance from second side edge104for securing assembly100to a stud (not shown) with fasteners (not shown). In certain exemplary embodiments, a viewing window112may be included in planar portion108to easily find and view any markings made in the stud (not shown) to which assembly100is to be attached.

Planar portion108also comprises at least two spaced-apart apertures114between second side edge104and holes110for securing a bracket (not shown) and/or additional electrical box (not shown) on the side of the stud opposite to the openings106a,106b. The section extending from the second side edge104to about midway of the planar portion108and including the apertures114makes up a first portion of the assembly. The section extending from about midway of the planar portion108to the apertures106band including holes110makes up a second portion of the assembly. The section between the first edge102and the openings106bmakes up a third portion of the assembly100.

Assembly100further comprises an open portion116therein. Open portion116is disposed closer to first side edge102than to second side edge104and is positioned between openings106a,106b.Generally, open portion116does not extend onto planar portion108. A raised rib118is formed about the circumference of open portion116and extends outwardly from assembly100. Rib118has a height that is generally approximately equal to the thickness of a wall (not shown) behind which assembly100is positioned. In certain exemplary embodiments, rib118is integrally formed with assembly100. In alternative exemplary embodiments, rib118is a separate piece that is attached to the assembly100.

Referring toFIGS. 2A-2C, an electrical outlet box200is attached to combination mounting plate and cover assembly100, which is attached to a stud202having a wall204secured thereto. Electrical outlet box200can contain at least one electrical fixture206therein, such as a convenience outlet (as shown inFIG. 2A), an electrical switch, electrical terminals, or any other suitable device. Electrical outlet box200is connected to assembly100by multiple fasteners208received by openings106a,106b.Suitable examples of fasteners208include, but are not limited to, threaded screws, nuts and bolts, and other suitable fastening devices. Electrical outlet box200may be adjusted on assembly100by moving electrical outlet box200with respect to the elongated openings106a,106b.

Assembly100with the attached outlet box200is placed adjacent to stud202such that outlet box200contacts at least a portion of a side wall202aof stud202and such that planar portion108is disposed against a front face202bof stud202and extends beyond an opposite side wall202cof stud202. In some embodiments, electrical outlet box200may solidly abut side wall202aof stud202and horizontal and angular movement of assembly100with respect to stud202may be substantially reduced or prevented. Further, any deflectional movement with respect to stud202may be limited. Fasteners210are disposed in holes110in planar portion108for securing assembly100to stud202such that movement of assembly100in any direction is substantially prevented. Fasteners210may be any common fastener. For instance, when stud202is wood, fasteners210may be a wood screw, nail, or other suitable fastener. When stud202is metal, fasteners210may be a self-tapping metal screw, rivet, nut and bolt, or other suitable fastener.

In certain exemplary embodiments, assembly100may further comprise a far-side support212(FIG. 2C) to further support assembly100such that assembly100does not deflect, or shift in a direction perpendicular to wall204, when force is applied to assembly100or to a component attached thereto. Far-side support212is connected to first side edge102of assembly100, and extends from assembly100to wall204. In an exemplary embodiment, far side support212is integrally formed with the assembly100.

Assembly100and outlet box200are covered by a wall (not shown) such that an opening in the wall receives raised rib118of assembly100. A surface118aof rib118is substantially flush with the outer surface of the wall due to the height of rib118being approximately the same as the thickness of the wall. Thus, electrical fixture206within the outlet box200may be readily accessible to a user.

Referring toFIGS. 3A-3B, a bracket300and an electrical outlet box302are attached to the combination mounting plate and cover assembly100. In certain exemplary embodiments, electrical outlet box302is similar to electrical outlet box200. Suitable examples of brackets300that may be attached to assembly100include, but are not limited to, box mounting brackets and box supports in product line BB4-23 commercially available from Cooper B-Line®, Inc. and Caddy® H23 mounting brackets commercially available from Erico International Corp. Bracket300and electrical outlet box302are secured to assembly100, and assembly100is secured to stud202as shown inFIGS. 2A-2C.

Bracket300and electrical outlet box302are secured to assembly100on the side of stud202opposite to the electrical outlet box200using fasteners304through apertures114. Suitable examples of fasteners304include, but are not limited to, threaded screws, nuts and bolts, and other suitable fastening devices. The configuration of assembly100allows for a bracket300and/or second electrical outlet box302to be attached to the side of stud202that is opposite to the electrical outlet box200, and thus allows mounting of multiple devices to a single assembly and results in improved field flexibility and efficiency.

Referring toFIGS. 4A-4B, another exemplary combination mounting plate and cover assembly400is illustrated as a single unitary member. Assembly400is similar to assembly100with the difference being in the planar portion. Planar portion402comprises a leg404that extends orthogonal to and outwardly therefrom towards wall204. In an exemplary embodiment, leg404may be formed by cutting three sides of a rectangular portion of planar portion402and bending the cut portion away from assembly400along the uncut side of the rectangular portion. In an alternative exemplary embodiment, leg404may be formed integrally with the assembly400during a molding process.

When assembly400is mounted to a stud406, leg404may solidly abut a side wall406aof stud406and thus substantially limit any horizontal or angular movement of assembly400with respect to stud406. Furthermore, any deflectional movement of assembly400with respect to stud406may be limited. While leg404is shown to be rectangular, one of ordinary skill in the art will recognize that leg404may be any other suitable shape, provided leg404can contact at least a portion of side wall406aof stud406. In certain exemplary embodiments, leg404may include apertures408through which fasteners410may be received to further secure assembly400to stud406. Similar to assembly100, a bracket300and electrical outlet box302may be attached via fasteners304through apertures114of assembly400to mount bracket300and electrical outlet box302on an opposite side406bof stud406.

Thus, assemblies100,400have the combined function of a box support, raised cover ring, and secondary bracket and/or outlet box mount, thereby providing cost efficiency by reducing the number of parts and the labor time to assemble and install as compared to conventional assemblies.

Generally, methods of the present invention include methods of mounting an electrical outlet box on one side of a stud on a wall of a building structure using a combination mounting plate and cover assembly, as well as mounting a bracket and/or second outlet box to the combination assembly on the opposite side of the stud. The user can secure an electrical outlet box to the combination assembly and adjacent a stud, secure the combination assembly to the stud with the electrical outlet box disposed on one side of the stud, and secure a bracket and/or second outlet box to the combination assembly on the opposite side of the stud. One having ordinary skill in the art will realize that the user may complete these steps in any order.

Therefore, the present invention is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present invention may be modified and practiced in different but equivalent manners apparent to those having ordinary skill in the art having the benefit of the teachings herein. Having described some exemplary embodiments of the present invention, it is believed that the combination mounting plate and cover assemblies may be formed in a variety of sizes having any desired size of open portion to permit the use of more than one fixture within the electrical outlet box. The use of ganged fixtures also is possible. While numerous changes may be made by those having ordinary skill in the art, such changes are encompassed within the spirit and scope of this invention as defined by the appended claims. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present invention as defined by the claims below. The terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee.