Multi-gang adjustable mud ring assemblies

A mud ring assembly includes base member, raised member, telescoping member and plurality of drive members. The base member has a flange and an opening through the flange. The raised member extends from the base member and follows the opening in the flange to form a raised wall. The raised member has a plurality of mounting tabs extending from the raised wall toward the opening in the raised member. The telescoping member is positioned within the raised member opening and is movable relative to the raised member between a retracted position and an extended position. The telescoping member has a wall, an opening and a plurality of mounting tabs extending from the wall toward the opening in the telescoping member. Rotation of the drive members causes the telescoping member to move between the retracted position and the extended position.

BACKGROUND

Field

The present disclosure relates generally to mud rings, and more particularly to adjustable multi-gang mud ring assemblies.

Description of the Related Art

Electrical devices (e.g., electrical outlets, switches, and others) are typically installed in a wall or ceiling. A multi-gang or single gang junction box is typically secured to a stud or support beam inside the wall or ceiling. In multi-gang boxes, typically more than one electrical device is installed in the box. The electrical devices are then secured in the box in electrical communication with electrical conductors so that the electrical devices extend or protrude from the wall or ceiling. In this manner, any exposed portion of the electrical conductor and their connections to the electrical devices are shielded within the box. Plaster rings, extension rings, and extenders, commonly known as mud rings, are typically attached to the box prior to the installation of sheet rock, wall board, or other covering surface material.

SUMMARY

The present disclosure provides exemplary embodiments of multi-gang mud ring assemblies. In an exemplary embodiment, a multi-gang mud ring assembly includes a base member, a raised member, a telescoping member and a plurality of drive members. The base member has a flange and a rectangular or square opening through the flange. The raised member extends from the base member and follows the rectangular or square opening in the flange to form a rectangular or square raised wall. The raised member has a plurality of mounting tabs extending from the raised wall into the rectangular or square opening. The plurality of mounting tabs are substantially perpendicular to the raised wall. The telescoping member is positioned within the raised member and is movable within and relative to the raised member between a retracted position and an extended position. The telescoping member has a rectangular or square wall and a plurality of mounting tabs extending from the rectangular or square wall into the rectangular or square opening, such that the plurality of mounting tabs are substantially perpendicular to the rectangular or square wall. In this configuration, one of the plurality of mounting tabs on the telescoping member is aligned with one of the mounting tabs on the raised member to define a mounting tab pair. The rectangular or square wall of the telescoping member includes a plurality of protective members. In this configuration, one protective member is positioned in proximity to one of the mounting tab pairs. In this configuration, one of the plurality of drive members is operatively coupled to one or both mounting tabs of one of the mounting tab pairs such that rotation of the drive members cause the telescoping member to move between the retracted position and the extended position.

In an exemplary embodiment, a multi-gang mud ring assembly includes a base member, a raised member, a telescoping member and a plurality of drive members. The base member has a flange and a substantially rectangular or square opening through the flange. The raised member extends from the base member and follows the opening in the flange to form a substantially rectangular or square raised wall. The raised member has a plurality of mounting tabs extending from the raised wall toward the opening. The telescoping member is positioned within the raised member and movable within the raised member between a retracted position and an extended position. The telescoping member has a substantially rectangular or square wall and a plurality of mounting tabs extending from the wall toward a center of the opening such that one of the plurality of mounting tabs of the telescoping member is aligned with one of the mounting tabs on the raised member to define a mounting tab pair. One of the plurality of drive members is operatively coupled to the mounting tabs of one of the mounting tab pairs such that rotation of the drive member causes the telescoping member to move between the retracted position and the extended position.

In an exemplary embodiment, a rectangular or square mud ring kit includes an electrical box and a mud ring assembly. The mud ring assembly includes a base member, a raised member, a telescoping member and a plurality of drive members as described herein.

DETAILED DESCRIPTION

The present disclosure provides exemplary embodiments of adjustable mud ring assemblies for electrical boxes and kits that include an adjustable mud ring assembly according to the present disclosure and an electrical box to which the adjustable mud ring assembly can be secured. As shown inFIGS.1and2, one exemplary embodiment of the present disclosure depicts a three-gang electrical box500with a three-gang adjustable mud ring assembly10secured to the electrical box500, where the three-gang adjustable mud ring assembly10can be used when securing three electrical devices510to the electrical box. As shown inFIGS.14and15, another exemplary embodiment of the present disclosure depicts a two-gang electrical box520with a two-gang adjustable mud ring assembly100secured to the electrical box520, where the two-gang adjustable mud ring assembly100can be used when securing two electrical devices510to the electrical box. It is noted that while three-gang boxes and mud ring assemblies are shown inFIGS.1and2, and two-gang boxes and mud ring assemblies are shown inFIGS.14and15, the present disclosure also contemplate other multi-gang boxes and multi-gang mud ring assemblies. As shown inFIGS.27and28, another exemplary embodiment of the present disclosure depicts a single-gang electrical box520with a single-gang adjustable mud ring assembly200secured to the electrical box520, where the single-gang adjustable mud ring assembly200can be used to secure a single electrical device510to the electrical box. The adjustable mud ring assemblies10,100and/or200are typically attached to an electrical box500or520prior to the installation of a surface covering material530, such as drywall, sheetrock, wall board, cement backer board, fiber cement backer board, or other surface covering materials. The electrical box500and/or520and adjustable mud ring assemblies10,100and/or200can be installed in different orientations to conform to a desired or required orientation of the electrical device510to be attached to the adjustable mud ring assembly.

The electrical devices510contemplated by the present disclosure include, for example, electrical switches and electrical receptacles. For ease of description, the electrical devices may also be referred to herein collectively as the “devices” in the plural, and the “device” in the singular. The electrical boxes500and520may be made of metal or plastic. Non-limiting examples of metal electrical boxes include steel, aluminum and aluminum alloy boxes. Non-limiting examples of plastic electrical boxes include PVC boxes and other molded plastic boxes. The electrical boxes are typically multi-gang or single-gang rectangular or square boxes, and for ease of description may be referred to herein as the “boxes” in the plural and the “box” in the singular. The adjustable mud ring assemblies10,100and/or200according to the present disclosure may be made of metal or plastic. Non-limiting examples of metal adjustable mud ring assemblies include steel, aluminum and aluminum alloy adjustable mud ring assemblies. Non-limiting examples of plastic adjustable mud ring assemblies include PVC adjustable mud ring assemblies and other molded plastic adjustable mud ring assemblies. For ease of description, the adjustable mud ring assemblies may also be referred to herein as the “mud rings” in the plural and the “mud ring” in the singular.

Referring now toFIGS.3and9, an exemplary embodiment of a mud ring kit550is shown. The mud ring kit550includes a mud ring assembly10and an electrical box500. In this exemplary embodiment, the electrical box500is sufficiently sized so that a three-gang mud ring assembly10can be secured to the electrical box. Referring toFIGS.4-8and10-13, the exemplary three-gang mud ring assembly10according to the present disclosure includes a base member20, a raised member40, a movable or telescoping member60, and one or more drive members90.

Referring toFIGS.4-8, the base member20includes a substantially planar flange22and an opening24in the flange, seen inFIG.4. The flange22includes one or more mounting openings26, e.g., keyhole slots, used for securing the base member20to a box500. The raised member40of the mud ring assembly10extends from a top surface22aof the flange22to provide a substantially rectangular or square wall42having a height “H1” and the inside opening24has a length “L1” and a width “W1.” The height “H1” of the wall42is preferably set to coincide with a minimum thickness of a surface covering material530, seen ifFIGS.1and2, through which at least a portion of the mud ring assembly10may extend. For example, if the thickness of the surface covering material530is to be ½ inch, the height of the wall42of the raised member40would be between about ⅜ of an inch and about ¾ of an inch. The inside opening24in the raised member40is preferably set to receive the telescoping member60and multiple devices510, and may be less than an opening of the electrical box500. For example, if the opening of a three-gang electrical box is in the range of about 9 inches by about 5 inches, the inside opening24would have a length “L1” in the range of about 5 inches to about 6 inches, and a width “W1” in the range of about 3 inches to about 4 inches. The raised member40extends around or along the opening24of the base member20. The raised member40may be integral with or monolithically formed into the base member20. In another embodiment, the raised member40may be secured to the base member20using, for example, welds or mechanical fasteners. The raised member40includes one or more mounting tabs44, seen inFIG.5, that extend from the wall42of the raised member40into the opening24such that the mounting tabs44are substantially perpendicular to the wall42. Each mounting tab44includes an aperture46configured and dimensioned to operatively interact with one of the one or more drive members90such that activation of the drive members90can move the telescoping member60between a retracted position, seen inFIGS.3and4, and a fully extended position, seen inFIGS.9and12. In the exemplary embodiment shown, the apertures46are threaded holes and the drive members90are threaded fasteners.

Referring toFIGS.3,7and8, the telescoping member60includes a wall62, e.g., a rectangular or square wall, that may be formed from a plurality of interlocking wall segments, or the rectangular or square wall62may be formed as a unitary or monolithic wall. In the embodiment shown, the wall62is formed from a plurality of interlocking wall segments62a,62b,62cand62d. Each wall segment62a,62b,62cand62dhas a height “H2,” seen inFIG.7, and when the wall segments are interlocked has an outer length “L2” and an outer width “W2,” seen inFIG.7. The height “H2” is preferably set to provide a desired maximum extension of the mud ring assembly10. For example, if the desired maximum extension of the mud ring assembly10is to be about 2 inches, the height “H2” of the telescoping member60would be in the range of about ¾ of an inch and about 2 inches. The outer length “L2” of the telescoping member60is less than the length “L1” of the of the raised member40, and the outer width “W2” of the telescoping member60is less than the width “W1” of the of the raised member40so that the telescoping member60fits within the opening24within the raised member40so that the telescoping member60is movable relative to the base member20and the raised member40. The raised member40extends the depth of the opening24to the inside of the telescoping member60. Preferably, the outer length “L2” and the outer width “W2” are set to fit within a multi-gang, here a three-gang, electrical box500used for mounting electrical devices510to the mud ring assembly10. For example, if the length and width of a three-gang electrical box500is in a range of about 9 inches by about 5 inches, the outer length “L2” would be in a range of about 5 inches to about 6 inches and the outer width “W2” would be in a range of about 3 inches to about 4 inches.

Referring againFIGS.7and8, the telescoping member60includes one or more mounting tabs64that extend into the opening24such that the mounting tabs64are substantially perpendicular to the wall62of the telescoping member60. In the exemplary embodiment shown, the wall segment62bhas two mounting tabs64extending into the opening24, and the wall segment62dhas two mounting tabs64extending into the opening24. However, it is noted that the mounting tabs64may be on any wall segment62a-62dand at any location on the wall segments. The mounting tabs64are positioned on the wall segments62bor62dso that they align with a respective mounting tab44extending from the wall42of the raised member40. Each mounting tab64includes an aperture66, seen inFIGS.7and8, configured and dimensioned to receive one of the one or more drive members90, such that at least a portion of the drive member90can pass through mounting tab64, as seen inFIGS.6and9. The apertures66of the mounting tabs64are aligned with the apertures46of the respective mounting tabs44.

In the embodiment ofFIGS.1-13, there are four mounting tabs44on the raised member40and four mounting tabs64on the telescoping member60. The mounting tabs44are positioned on opposite sides of the wall42of the raised member40in close proximity to the corners of the wall42, as shown inFIG.5. Similarly, mounting tabs64are positioned on opposite sides of the wall62of the telescoping member60in close proximity to the corners of the wall62, as shown inFIG.7. As shown inFIGS.6and13, a first mounting tab44of the raised member40is aligned with a first mounting tab64of the telescoping member60to form a first mounting tab pair. In this configuration, the aperture46in the first mounting tab44is aligned with the aperture66in the first mounting tab64so that a first drive member90can pass into operative engagement with the aperture46. A head94of the first drive member90passes at least partially into the aperture66in the first mounting tab64. Similarly, a second mounting tab44of the raised member40is aligned with a second mounting tab64of the telescoping member60to form a second mounting tab pair. In this configuration, the aperture46in the second mounting tab44is aligned with the aperture66in the second mounting tab64so that a second drive member90can pass into operative engagement with the aperture46in the second mounting tab44. A head94of the second drive member90passes at least partially into the aperture66in the second mounting tab64. A third mounting tab44of the raised member40is aligned with a third mounting tab64of the telescoping member60to form a third mounting tab pair. In this configuration, the aperture46in the third mounting tab44is aligned with the aperture66in the third mounting tab64so that a third drive member90can pass into operative engagement with the aperture46in the third mounting tab44. A head94of the third drive member90passes at least partially into the aperture66in the third mounting tab64. Similarly, a fourth mounting tab44of the raised member40is aligned with a fourth mounting tab64of the telescoping member60to form a fourth mounting tab pair. In this configuration, the aperture46in the fourth mounting tab44is aligned with the aperture66in the fourth mounting tab64so that a fourth drive member90can pass into operative engagement with the aperture46in the fourth mounting tab44. A head94of the fourth drive member90passes at least partially into the aperture66in the fourth mounting tab64. Is it noted that the mounting tabs44on the raised member40act as a first stop that engage the mounting tabs64on the telescoping member60. More specifically, as the telescoping member60is being moved to the retracted position by the drive members90, the mounting tabs64move toward the mounting tabs44of the raised member40. When the mounting tabs64contact the mounting tabs44, the telescoping member60is in the retracted position and the mounting tabs44stop the telescoping member60from moving through the opening24and through the base20.

Continuing to refer toFIGS.6-8, the wall segments62aand62cinclude one or more interlocking members68, which in the exemplary embodiment shown are hook shaped members with an arm68aand a hook68b. The arm68aextends from the wall segment62aor62cso that the arm68ais substantially perpendicular to a side edge of the wall segment. The hook68bis attached to the arm68aas shown inFIG.7. The interlocking members68may be integrally or monolithic formed into the wall segment, e.g., wall segment62aor62c. In another embodiment, the interlocking members68may be separate members secured to the wall segments62using welds or mechanical fasteners. Similarly, the arm68aand hook68bmay be integrally of monolithically formed members, or the arm68aand hook68bmay be separate members joined together using, for example, welds.

Referring again toFIGS.7and8, the telescoping member60also includes one or more stop arms70provided to stop movement of the telescoping member60when the telescoping member reaches the fully extended position, seen inFIGS.9and12. The stop arm70extends at or near a bottom edge65of the wall62so that the stop arm70is positioned to engage the mounting tab44of the raised member40. In the exemplary embodiment shown, each wall segment62band62dincludes two stop arms70extending at or near a bottom edge65of the wall segments so that the stop arm70is positioned to engage the mounting tab44of the raised member40when the telescoping member60reaches the fully extended position. With the stop arm70positioned to engage or contact the mounting tab44of the raised member40, as the telescoping member60is moved to the fully extended position by the drive members90, the stop arm70moves toward the mounting tab44of the raised member40. When the stop arm70contacts the mounting tab44, the telescoping member60is in the fully extended position.

As shown inFIGS.7and8, the telescoping member60includes one or more protective members72that are provided to prevent electrical wires withing an electrical box500from contacting the drive members90. As noted above, in the embodiment shown there are four sets of mounting tabs44and64, where the apertures46and66of the first mounting tab pair are aligned, the apertures46and66of the second mounting tab pair are aligned, the apertures46and66of a third mounting tab pair are aligned, and the apertures46and66of the fourth mounting tab pair are aligned. A first drive member90extends at least partially through the first mounting tab pair and is operatively coupled to the first mounting tab44. A second drive member90extends at least partially through the second mounting tab pair and is operatively coupled to the second mounting tab44. A third drive member90extends at least partially through the apertures46and66of the third mounting tab pair and is operatively coupled to the third mounting tab44. And, a fourth drive member90extends at least partially through the apertures46and66of the fourth mounting tab pair and is operatively coupled to the fourth mounting tab44. In this configuration, there are also four protective members72. The first protective member72is associated with the first mounting tab pair and first drive member90, the second protective member72is associated with the second mounting tab pair and the second drive member90, the third protective member72is associated with the third mounting tab pair and the third drive member90, and the fourth protective member72is associated with the fourth mounting tab pair and the fourth drive member90. Each protective member72includes a shroud74and an alignment post76. In one embodiment, the shroud74is integral with or monolithically formed into the wall62of the telescoping member60. In another embodiment, the shroud74of the of the protective member72may be secured to the wall62by welds, adhesives or mechanical fasteners. The shroud74can extend from at or near the bottom edge65of the wall62toward the top edge63of the wall62, or the shroud74can extend from the bottom edge65of the wall62to a point between the bottom edge65and the top edge63of the wall62. In the exemplary embodiment shown, the shroud74extends from the bottom edge65of the wall segments62band62dto a point between the bottom edge65and the top edge63of the wall62sufficient to prevent electrical wires within the electrical box500from contacting the drives members90.

Referring again toFIGS.7and8, the telescoping member60also includes one or more device mounting tabs78used to secure a device510to the mud ring assembly10. In the embodiment shown, the telescoping member60includes six device mounting tabs78that extend from the top edge63of the wall62toward the opening24. As noted above, the opening24is the combination of the opening in the base member20, the opening in the raised member40and the opening in the telescoping member60. The device mounting tabs78extend or protrude from the wall62so that they are substantially perpendicular to the wall62. In the exemplary embodiment shown, the device mounting tabs78are positioned on opposite wall segments62aand62cof the telescoping member60and separated a sufficient distance so that a device can be secured to opposing device mounting tabs78, as shown inFIGS.1and2.

Referring again toFIG.6, each of the one more drive members90is operatively coupled to a mounting tab44of the raised member40via the aperture46. As such, the drive members90are positioned within the opening24of the mud ring assembly10. In the exemplary embodiment shown, the mud ring assembly10includes four drive members90. Each drive member90is a fastener including a threaded shank92, a head94and a flange96positioned between the threaded shank92and the head94. The head94fits within the aperture66in the mounting tab64and the flange96is provided to engage the mounting tab64to move the telescoping member60toward the fully extended position when the drive members are rotated counter-clockwise. To move the telescoping member60to the retracted position, the drive members90are rotated clockwise so that the flange96engages the interlocking members68of the telescoping member60to push the telescoping member60toward the retracted position. It is noted that the hook68bof the interlocking members68wrap at least partially around the drive members90, as shown inFIG.6.

During installation, an installer can rotate the drive members90to thread or unthread the threaded shanks92relative to the mounting tabs44, thus changing the position of the telescoping member60relative to the base member20and raised member40. In this manner, the installer may adjust the depth of the telescoping member60between the retracted position and the fully extended position as necessary to accommodate various wall thicknesses and various box depths. As noted above, the stop arm70on the wall62of the telescoping member60engages the mounting tab44to prevent the telescoping member from moving past the fully extended position, and the mounting tabs44of the raised member40act as a stop to prevent the telescoping member60from moving past the retracted position.

Referring now toFIGS.16and22, another exemplary embodiment of a mud ring kit560is shown. The mud ring kit560includes a mud ring assembly100and an electrical box520. In this exemplary embodiment, the electrical box520is sufficiently sized so that a two-gang mud ring assembly100can be secured to the electrical box. Referring toFIGS.17-21and23-26, the exemplary two-gang mud ring assembly100according to the present disclosure includes a base member120, a raised member140, a movable or telescoping member160, and one or more drive members190.

Referring toFIGS.16-19, the base member120includes a substantially planar flange122and an opening124in the flange. The flange122includes one or more mounting openings126, e.g., keyhole slots, used for securing the base member120to a box520. The raised member140of the mud ring assembly100extends from a top surface122aof the flange122to provide a substantially rectangular or square wall142having a height “H3,” seen inFIG.16, and the inside opening124of the raised member has a length “L3” and a width “W3.” The height “H3” of the wall142is preferably set to provide a minimum height to stabilize the telescoping member160within the opening24in the raised member40as the telescoping member moves between a retracted position and a fully extended position. For example, the height “H3” of the wall142of the raised member40may be between about 1/32 of an inch and about ½ of an inch. The inside opening124in the raised member140is preferably set to receive the telescoping member160and multiple devices510, and may be less than an opening of the electrical box520. For example, if the opening of a two-gang electrical box is in the range of about 4 inches by about 4 inches, the inside opening124would have a length “L3” in the range of about 3 inches to about 4 inches, and a width “W3” in the range of about 3 inches to about 4 inches. The raised member140extends substantially along or around the opening124of the base member120. The raised member140may be integral with or monolithically formed into the base member120. In another embodiment, the raised member140may be secured to the base member120using, for example, welds or mechanical fasteners. The raised member140includes one or more mounting tabs144, seen inFIG.18, that extend from the wall142of the raised member140into the opening124such that the mounting tabs144are substantially perpendicular to the wall142. Each mounting tab144includes an aperture146configured and dimensioned to operatively interact with one of the one or more drive members190such that activation of the drive members190can move the telescoping member160between a retracted position, seen inFIGS.26and27, and a fully extended position, seen inFIGS.22and25. In the exemplary embodiment shown, the apertures146are threaded holes and the drive members190are threaded fasteners.

Referring toFIGS.20and21, the telescoping member160includes a wall162, e.g., a square or rectangular wall, that may be formed from a plurality of interlocking wall segments, or the square or rectangular wall162may be formed as a unitary or monolithic wall. In the embodiment shown, the wall162is formed from a plurality of interlocking wall segments162aand162b. In this exemplary embodiment, each wall segment162aand162bis a substantially U-shaped member that when interlocked form a substantially square shape. Each wall segment162aand62bhas a height “H4,” seen inFIG.20, and when the wall segments are interlocked has an outer length “L4” and an outer width “W4,” seen inFIG.20. The height “H4” is preferably set to provide a desired maximum extension of the mud ring assembly100. For example, if the desired maximum extension of the mud ring assembly100is to be about 1-2 inches, the height “H4” of the telescoping member160would be in the range of about ¾ of an inch to about 2 inches. The outer length “L4” of the telescoping member160is less than the length “L3” of the of the raised member140, and the outer width “W4” of the telescoping member160is less than the width “W3” of the of the raised member40so that the telescoping member160fits within the opening124within the raised member140so that the telescoping member160is movable relative to the base member120and the raised member140. The raised member140extends the depth of the opening124to the inside of the telescoping member160. Preferably, the outer length “L4” and the outer width “W4” are set to fit within a multi-gang, here a two-gang, electrical box520used for mounting electrical devices510to the mud ring assembly100. For example, if the length and width of a two-gang electrical box520is in a range of about 4 inches by about 4 inches, the outer length “L4” would be in a range of about 3 inches to about 4 inches and the outer width “W4” would be in a range of about 3 inches to about 4 inches.

Continuing to refer toFIGS.19-21, the telescoping member160includes one or more mounting tabs164that extend into the opening124such that the mounting tabs164are substantially perpendicular to the wall162of the telescoping member160. In the exemplary embodiment shown, the wall segment162ahas one mounting tab164at one end of the wall segment that extends into the opening124of the telescoping member160. Similarly, the wall segment162bhas one mounting tab164at one end of the wall segment that extends into the opening124of the telescoping member160. However, it is noted that the mounting tabs164may be at any location along the wall segments162aand162b. The mounting tabs164are positioned on the wall segments162aor162bso that they align with a respective mounting tab144extending from the wall142of the raised member140. Each mounting tab164includes an aperture166, seen inFIGS.20and21, configured and dimensioned to at least partially receive one of the one or more drive members190, such that at least a portion of the drive member190can pass through mounting tab164, as seen inFIG.19. The apertures166of the mounting tabs164are aligned with the apertures146of the respective mounting tabs144.

In the embodiment ofFIGS.14-26, there are two mounting tabs144on the raised member140and two mounting tabs164on the telescoping member160. The mounting tabs144are positioned on opposite sides of the wall142of the raised member140in close proximity to a center of the wall142, as shown inFIG.18. Similarly, mounting tabs164are positioned on opposite sides of the wall162of the telescoping member160in close proximity to a center of the wall162, as shown inFIG.20. As shown inFIG.19, a first mounting tab144of the raised member140is aligned with a first mounting tab164of the telescoping member160to form a first mounting tab pair. In this configuration, the aperture146in the first mounting tab144is aligned with the aperture166in the first mounting tab164so that a first drive member190can pass into operative engagement with the aperture146. A head194of the first drive member190passes at least partially into the aperture166in the first mounting tab164. Similarly, a second mounting tab144of the raised member140is aligned with a second mounting tab164of the telescoping member160to form a second mounting tab pair. In this configuration, the aperture146in the second mounting tab144is aligned with the aperture166in the second mounting tab164so that a second drive member190can pass into operative engagement with the aperture146in the second mounting tab144. A head194of the second drive member190passes at least partially into the aperture166in the second mounting tab164.

Continuing to refer toFIGS.19-21, the wall segments162aand162balso include one or more interlocking members168, which in the exemplary embodiment shown are dowels that engage corresponding circular holes169in the segment walls162aand162binclude. The interlocking members168may be integrally or monolithic formed into the wall segments, e.g., wall segment62aor62b. In another embodiment, the interlocking members168may be separate members secured to the wall segments162using, for example, welds.

As shown inFIGS.20-26, the telescoping member160includes one or more protective members172positioned at one end of each wall segment162aand162b, as shown. The one or more protective members172are provided to prevent electrical wires withing an electrical box520from contacting the drive members190. As noted above, in the embodiment shown there are two pairs of mounting tabs144and164, where the apertures146and166of the first mounting tab pair are aligned, and the apertures146and166of the second mounting tab pair are aligned. A first drive member190extends at least partially through the first mounting tab pair and is operatively coupled to the first mounting tab144. A second drive member190extends at least partially through the second mounting tab pair and is operatively coupled to the second mounting tab144. In this configuration, there are also two protective members172. The first protective member172is associated with the first mounting tab pair and first drive member190, and the second protective member172is associated with the second mounting tab pair and the second drive member190. Each protective member172, seen inFIGS.20and21, includes a shroud174and an alignment post176. In one embodiment, the shroud174is integral with or monolithically formed into the wall162of the telescoping member160. In another embodiment, the shroud174of the of the protective member172may be secured to the wall162by welds, adhesives or mechanical fasteners. The shroud174can extend from at or near the bottom edge165of the wall162toward the top edge163of the wall162, or the shroud174can extend from the bottom edge165of the wall162to a point between the bottom edge165and the top edge163of the wall162. In the exemplary embodiment shown, the shroud174extends from the bottom edge165of the wall segments162aand162bto a point between the bottom edge165and the top edge163of the wall162sufficient to prevent electrical wires within the electrical box520from contacting the drives members190.

Referring again toFIGS.20and21, the wall segments162aand162binclude one or more first stop arms150connected between the mounting tab164and the wall segment162aor162b, as seen inFIG.20. A bottom edge150aof the first stop arm150is spaced from the mounting tab164to a distance that preferably coincides with a minimum thickness of a surface covering material530, seen inFIG.20, through which a portion of the mud ring assembly100may extend. The first stop arm150is provided to engage the mounting tabs144on the raised member140. More specifically, as the telescoping member160is being moved to the retracted position by the drive members90, the mounting tabs164and the first stop arm150move toward the mounting tabs144of the raised member140. When the bottom edge150aof the first stop arms150contacts the mounting tabs144, the telescoping member160is in the retracted position and the mounting tabs144stop the telescoping member160from moving through the opening124and through the base120.

Referring toFIGS.23and24, the telescoping member160also includes one or more second stop arms170provided to stop movement of the telescoping member160when the telescoping member reaches the fully extended position, seen inFIG.23. The stop arm170extends from the wall162at or near a bottom edge65so that the stop arm170is positioned to engage the mounting tab144of the raised member140. In the exemplary embodiment shown, each wall segment162aand162bincludes one stop arm170extending at or near a bottom edge165of the wall segments so that the stop arm170is positioned to engage the mounting tab144of the raised member140when the telescoping member160reaches the fully extended position, as seen inFIG.24. More specifically, with the stop arms170positioned to engage or contact the mounting tabs144of the raised member140, as the telescoping member160is moved to the fully extended position by the drive members190the stop arm170moves toward the mounting tab144of the raised member140. When the stop arm170contacts the mounting tab144, the telescoping member160is in the fully extended position.

Referring again toFIGS.20and21, the telescoping member160also includes one or more device mounting tabs178used to secure a device510to the mud ring assembly100. In the embodiment shown, the telescoping member160includes four device mounting tabs178that extend from the top edge163of the wall162into the opening124of the telescoping member160. As noted above, the opening124is the combination of the opening in the base member120, the opening in the raised member140and the opening in the telescoping member160. The device mounting tabs178extend or protrude from the wall162so that they are substantially perpendicular to the wall162. In the exemplary embodiment shown, the device mounting tabs178are positioned on opposite sides of the wall162of the telescoping member160and separated a sufficient distance so that a device510can be secured to opposing device mounting tabs178, as shown inFIGS.14and15.

Referring again toFIG.19, each of the one more drive members190is operatively coupled to a mounting tab144of the raised member140via the aperture146. As such, the drive members190are positioned within the opening124of the mud ring assembly100. In the exemplary embodiment shown, the mud ring assembly100includes two drive members190. Each drive member190is a fastener including a threaded shank192, a head194and a flange196positioned between the threaded shank192and the head194. The head194fits within the aperture166in the mounting tab164and the flange196is provided to engage the mounting tab164to move the telescoping member160toward the fully extended position when the drive members190are rotated counter-clockwise. To move the telescoping member160to the retracted position, the drive members190are rotated clockwise so that the flange196engages the first stop arm150of the telescoping member160to push the telescoping member160toward the retracted position.

During installation, an installer can rotate the drive members190to thread or unthread the threaded shanks192relative to the mounting tabs144, thus changing the position of the telescoping member160relative to the base member120and raised member140. In this manner, the installer may adjust the depth of the telescoping member160between the retracted position and the fully extended position as necessary to accommodate various wall thicknesses and various box depths. As noted above, the first stop arms150of the telescoping member160prevent the telescoping member160from moving past the retracted position, and the stop arms170on the wall162of the telescoping member160engages the mounting tab144to prevent the telescoping member from moving past the fully extended position.

Referring now toFIGS.29and35, another exemplary embodiment of a mud ring kit570is shown. The mud ring kit570includes a mud ring assembly200and an electrical box520. In this exemplary embodiment, the electrical box520is sufficiently sized so that a single-gang mud ring assembly200can be secured to the electrical box. Referring toFIGS.30-34and36-39, the exemplary single-gang mud ring assembly200according to the present disclosure includes a base member220, a raised member240, a movable or telescoping member260, and one or more drive members290.

Referring toFIGS.29-31, the base member220includes a substantially planar flange222and an opening224in the flange. The flange222includes one or more mounting openings226, e.g., keyhole slots, used for securing the base member220to a box520. The raised member240of the mud ring assembly200extends from a top surface222aof the flange222to provide a substantially rectangular or square wall242having a height “H5,” seen inFIG.29, and the inside opening224of the raised member240has a length “L5” and a width “W5,” seen inFIG.31. The height “H5” of the wall242is preferably set to provide a minimum height to stabilize the telescoping member260within the opening224in the raised member240as the telescoping member260moves between a retracted position and a fully extended position. For example, the height “H5” of the wall242of the raised member240may be between about 1 inch and about 2 inches. The inside opening224of the raised member240is preferably set to receive the telescoping member260and a single device510, and may be less than an opening of the electrical box520. For example, if the opening of a two-gang electrical box is in the range of about 4 inches by about 4 inches, the inside opening224would have a length “L5” in the range of about 3 inches to about 4 inches, and a width “W5” in the range of about 1 inch to about 3 inches. The raised member240extends substantially along or around the opening224of the base member220. The raised member240may be integral with or monolithically formed into the base member220. In another embodiment, the raised member240may be secured to the base member220using, for example, welds or mechanical fasteners. The raised member240includes one or more mounting tabs244, seen inFIG.31, that extend from the wall242of the raised member240into the opening224such that the mounting tabs244are substantially perpendicular to the wall242. Each mounting tab244includes an aperture246configured and dimensioned to operatively interact with one of the one or more drive members290such that activation of the drive members290can move the telescoping member260between a retracted position, seen inFIGS.29and30, and a fully extended position, seen inFIGS.35and36. In the exemplary embodiment shown, the apertures246are threaded holes and the drive members290are threaded fasteners.

Referring toFIGS.33and34, the telescoping member260includes a wall262, e.g., a square or rectangular wall, that may be formed from a plurality of interlocking wall segments, or the square or rectangular wall262may be formed as a unitary or monolithic wall. In the embodiment shown, the wall262is formed from a plurality of interlocking wall segments262aand262b. In this exemplary embodiment, each wall segment262aand262bis an L-shaped like member that when interlocked form a substantially square shape. Each wall segment262aand262bhas a height “H6,” seen inFIG.33, and when the wall segments are interlocked has an outer length “L6” and an outer width “W6,” seen inFIG.33. The height “H6” is preferably set to provide a desired maximum extension of the mud ring assembly200. For example, if the desired maximum extension of the mud ring assembly200is to be about 1-2 inches, the height “H6” of the telescoping member260would be in the range of about 1 inch to about 2 inches. The outer length “L6” of the telescoping member260is less than the length “L5” of the of the raised member240, and the outer width “W6” of the telescoping member260is less than the width “W5” of the of the raised member240so that the telescoping member260fits within the opening224within the raised member240so that the telescoping member260is movable relative to the base member220and the raised member240. The raised member240extends the depth of the opening224to the inside of the telescoping member260. Preferably, the outer length “L6” and the outer width “W6” are set to fit within a multi-gang, here a two-gang, electrical box520used for mounting electrical devices510, seen inFIGS.40and41, to the mud ring assembly200. For example, if the length and width of a two-gang electrical box520is in a range of about 4 inches by about 4 inches, the outer length “L6” would be in a range of about 3 inches to about 4 inches and the outer width “W6” would be in a range of about 1 inch to about 3 inches.

Continuing to refer toFIGS.33and34, the telescoping member260includes one or more mounting tabs264that extend into the opening224of the telescoping member260such that the mounting tabs264are substantially perpendicular to the wall262of the telescoping member260. In the exemplary embodiment shown, the wall segment262ahas one mounting tab264at one end of the wall segment that extends into the opening224. Similarly, the wall segment262bhas one mounting tab264at one end of the wall segment that extends into the opening224. However, it is noted that the mounting tabs264may be at any location along the wall segments262aand262b. The mounting tabs264are positioned on the wall segments262aor262bso that they align with a respective mounting tab244extending from the wall242of the raised member240. Each mounting tab264includes an aperture266, seen inFIGS.33and34, configured and dimensioned to at least partially receive one of the one or more drive members290, such that at least a portion of the drive member290can pass through mounting tab264, as seen inFIGS.32and35. The apertures266of the mounting tabs264are aligned with the apertures246of the respective mounting tabs244.

In the embodiment ofFIGS.27-39, there are two mounting tabs244on the raised member240and two mounting tabs264on the telescoping member260. The mounting tabs244are positioned on opposite sides of the wall242of the raised member240in close proximity to a center of the wall242, as shown inFIG.31. Similarly, mounting tabs264are positioned on opposite sides of the wall262of the telescoping member260in close proximity to a center of the wall262, as shown inFIGS.31and32. As shown inFIG.32, a first mounting tab244of the raised member240is aligned with a first mounting tab264of the telescoping member260to form a first mounting tab pair. In this configuration, the aperture246in the first mounting tab244is aligned with the aperture266in the first mounting tab264so that a first drive member290can pass into operative engagement with the aperture246. A head294of the first drive member290passes at least partially into the aperture266in the first mounting tab264. Similarly, a second mounting tab244of the raised member240is aligned with a second mounting tab264of the telescoping member260to form a second mounting tab pair. In this configuration, the aperture246in the second mounting tab244is aligned with the aperture266in the second mounting tab264so that a second drive member290can pass into operative engagement with the aperture246in the second mounting tab244. A head294of the second drive member290passes at least partially into the aperture266in the second mounting tab264.

Continuing to refer toFIGS.33and34, the wall segments262aand262balso include one or more interlocking members267and268. The interlocking members267, which in the exemplary embodiment shown, are dowels that engage corresponding circular holes269in the segment walls262aand262b. The interlocking members267may be integrally or monolithic formed into the wall segments, e.g., wall segment262aor262b. In another embodiment, the interlocking members267may be separate members secured to the wall segments262using, for example, welds. Interlocking members268, seen inFIG.34, which in the exemplary embodiment shown, are hook shaped members with an arm268aand a hook268b. The arm268aextends from the wall segment262aor262bso that the arm268ais substantially perpendicular to a side edge of the wall segment. The hook268bis attached to the arm268aas shown inFIGS.33and34. The interlocking members268may be integrally or monolithic formed into the wall segment, e.g., wall segment262aor262b. In another embodiment, the interlocking members268may be separate members secured to the wall segments262using welds or mechanical fasteners. Similarly, the arm268aand hook268bmay be integrally of monolithically formed members, or the arm268aand hook268bmay be separate members joined together using, for example, welds.

As shown inFIGS.33and34, the telescoping member260includes one or more protective members272positioned at one end of each wall segment262aand262b, as shown. The one or more protective members272are provided to prevent electrical wires withing an electrical box520from contacting the drive members290. As noted above, in the embodiment shown there are two pairs of mounting tabs244and264, where the apertures246and266of the first mounting tab pair are aligned, and the apertures246and266of the second mounting tab pair are aligned. A first drive member290extends at least partially through the first mounting tab pair and is operatively coupled to the first mounting tab244. A second drive member290extends at least partially through the second mounting tab pair and is operatively coupled to the second mounting tab244. In this configuration, there are also two protective members272. A first protective member272is associated with the first mounting tab pair and the first drive member290, and the second protective member272is associated with the second mounting tab pair and the second drive member290. Each protective member272includes a shroud274and an alignment post276. In one embodiment, the shroud274extends from the alignment post276. The shroud274may be integral with or monolithically formed into the alignment post276, or the shroud274of the of the protective member272may be secured to the alignment post276by welds, adhesives or mechanical fasteners. The alignment post276is interlocked with the wall262using the interlocking members267. The shroud274can extend from the wall262at or near the bottom edge265toward the top edge263of the wall262, or the shroud274can extend from the bottom edge265of the wall262to a point between the bottom edge265and the top edge263of the wall262. In the exemplary embodiment shown, the shroud274extends from the bottom edge265of the wall segments262aand262bto a point between the bottom edge265and the top edge263of the wall262sufficient to prevent electrical wires within the electrical box520from contacting the drives members290.

Referring toFIGS.33and34, the telescoping member260also includes one or more stop arms270provided to stop movement of the telescoping member260when the telescoping member reaches the fully extended position, seen inFIGS.36and37. The stop arms270extend from the wall262at or near a bottom edge265so that the stop arms270are positioned to engage the mounting tabs244of the raised member240. In the exemplary embodiment shown, each wall segment262aand262bincludes one stop arm270extending at or near a bottom edge265of the wall segments so that the stop arm270is positioned to engage a mounting tab244of the raised member240when the telescoping member260reaches the fully extended position, as seen inFIGS.36and37. More specifically, with the stop arms270positioned to engage or contact the mounting tab244of the raised member240, as the telescoping member260is moved to the fully extended position by the drive members290the stop arms270move toward the mounting tabs244of the raised member240. When the stop arms270contacts the mounting tab244, the telescoping member260is in the fully extended position.

Referring again toFIG.33, the telescoping member260also includes one or more device mounting tabs278used to secure a device510to the mud ring assembly200. In the embodiment shown, the telescoping member260includes two device mounting tabs278that extend from the top edge263of the wall262into the opening224of the telescoping member260. As noted above, the opening224is the combination of the opening in the base member220, the opening in the raised member240and the opening in the telescoping member260. The device mounting tabs278extend or protrude from the wall262so that they are substantially perpendicular to the wall262. In the exemplary embodiment shown, the device mounting tabs278are positioned on opposite sides of the wall262of the telescoping member260and separated a sufficient distance so that a device510can be secured to the device mounting tabs278, as shown inFIGS.27and28.

Referring again toFIG.32, each of the one more drive members290is operatively coupled to a mounting tab244of the raised member240via the aperture246. As such, the drive members290are positioned within the opening224of the mud ring assembly200. In the exemplary embodiment shown, the mud ring assembly200includes two drive members290. Each drive member290is a fastener including a threaded shank292, a head294and a flange296positioned between the threaded shank292and the head294. The head294fits within the aperture266in the mounting tab264and the flange296is provided to engage the mounting tab264to move the telescoping member260toward the fully extended position when the drive members290are rotated counter-clockwise. To move the telescoping member260to the retracted position, the drive members290are rotated clockwise so that the flange296engages the interlocking member268of the telescoping member260to push the telescoping member260toward the retracted position.

During installation, an installer can rotate the drive members290to thread or unthread the threaded shanks292relative to the mounting tabs244, thus changing the position of the telescoping member260relative to the base member220and raised member240. In this manner, the installer may adjust the depth of the telescoping member260between the retracted position and the fully extended position as necessary to accommodate various wall thicknesses and various box depths. As noted above, the interlocking members268of the telescoping member260prevent the telescoping member260from moving past the retracted position, and the stop arms270on the wall262of the telescoping member260engages the mounting tab244to prevent the telescoping member from moving past the fully extended position.

While illustrative embodiments of the present disclosure have been described and illustrated above, it should be understood that these are exemplary of the disclosure and are not to be considered as limiting. Additions, deletions, substitutions, and other modifications can be made without departing from the spirit or scope of the present disclosure. Accordingly, the present disclosure is not to be considered as limited by the foregoing description.