Electrical box mounting bracket with rails

An electrical installation bracket includes a body that may telescope to allow the length of the bracket to be changed to accommodate installation in different configurations, for example to accommodate different spacing between mounting studs. The bracket has rails on a face that allow an electrical box to be positioned, by sliding, at any of a variety of locations along the length of the body. The body has holes in it for securing the box to the bracket at a desired location along the body, with a front of the box for example protruding through an opening in the body. The body includes ears on opposite sides of the opening, with mounting holes for mounting the bracket to studs or other structure (or other hardware or devices). The electrical installation bracket advantageously provides more flexibility in placement of electrical boxes, with pre-prepared holes available for securing boxes.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention is in the field of electrical box mounts.

2. Description of the Related Art

Electrical boxes are widely used to mount electrical components, such as switches and outlets, and to contain electrical wiring connections. Installation and alignment of such boxing can be a time-consuming process.

SUMMARY OF THE INVENTION

According to various aspects of the invention, an electrical installation bracket includes a body having rails on a back side of the body, the rails allowing an electrical box or other item to be placed at various locations along the body of the bracket. The bracket may include one or more of the following features: the body has a pair of legs that define an opening therebetween; the box protrudes through or is accessible through the opening; the rails are on the legs; the rails extend all the way along the opening; the rails extend only partway along the opening; the rails are bent portions of the body; the body telescopes to change its length; the legs have holes in them to allow mounting of the box; the holes are regularly spaced over at least part of the legs; the holes are regularly spaced over substantially all (an entire length) of the legs; the electrical box(es) is/are secured to the legs using fasteners (such as screws) that engage the holes; the legs have tabs in them that can be bent to help hold the box in place at certain locations relative to the legs; the legs have markings on them that aid in placing the box at a desired location; the bracket is a single piece of material; the bracket is multiple pieces of material; the bracket is made of metal or plastic, such as steel; the opening is a rectangular opening; the body has ears, with mounting holes for mounting the bracket to one or more studs (or other structure); the body has ears with mounting holes for mounting the bracket to the one or more studs (or other structure); one or more of the ears may include one or more tabs to aid in positioning the bracket relative to structure; the bracket has a bottom for installation in a vertical configuration; the bottom includes a bendable foot that may be deployed (bent) to stabilize the bracket, for example engaging a footer or resting on a floor; the bottom may include tabs that may be bent inward to engage a footer, and may have holes for receiving screws for mounting on a footer or other structure; the bracket may have a top; and/or the top may include an angled flange.

According to other aspects of the invention, a method of installing an electrical box may include installing the bracket having any combination of the features of the other paragraphs of this summary or the detailed description; engaging the electrical box in the rails of the bracket; and securing the box to the bracket.

According to a further aspect of the invention, an electrical installation bracket includes: a body having a front face and a back face on opposite sides; and rails on one of the faces; wherein the rails extend on opposite sides of an opening in the bracket; and wherein the rails are able to receive an electrical box that may be secured to the bracket at least one location along the bracket, when the electrical box is engaged with the rails.

According another aspect of the invention, an electrical installation bracket includes: a body having a front face and a back face on opposite sides; rails on the back face; wherein the rails extend on opposite sides of an opening in the bracket; and wherein the bracket has holes therein for securing an electrical box in place at multiple locations along the bracket.

According to yet another aspect of the invention, an electrical installation bracket includes: a body having a front face and a back face on opposite sides; rails on one of the faces; wherein the rails extend on opposite sides of an opening in the bracket; wherein the rails are folded-over parts of the body; wherein the bracket secures an electrical box in at least one location along the bracket; wherein the bracket includes a pair of bracket parts that together make up the body; wherein the bracket parts are in a telescoping relationship that allows the bracket to be selectively changed in length; wherein the body has legs on opposite sides of the opening; wherein the legs have with respective rows of the holes for securing the electrical box to the legs; and wherein the body is made of metal or plastic.

According to still another aspect of the invention, an electrical installation bracket includes: a body having a front face and a back face on opposite sides; rails on one of the faces; wherein the rails extend on opposite sides of an opening in the bracket; wherein the bracket secures an electrical box in at least one location along the bracket; wherein the body has legs on opposite sides of the opening; wherein the holes are in the legs; wherein the legs have tabs in them that facilitate positioning the electrical box within the opening; and wherein the bracket is a single-piece bracket made of a unitary, continuous single piece of metal or plastic.

DETAILED DESCRIPTION

An electrical installation bracket includes a body that may telescope to allow the length of the bracket to be changed to accommodate installation in different configurations, for example to accommodate different spacing between mounting studs. The bracket has rails on a face that allow an electrical box to be positioned, by sliding, at any of a variety of locations along the length of the body. The body has holes in it for securing the box to the bracket at a desired location along the body, with a front of the box for example protruding through an opening in the body. The body includes ears on opposite sides of the opening, with mounting holes for mounting the bracket to studs or other structure (or other hardware or devices). The electrical installation bracket advantageously provides more flexibility in placement of electrical boxes, with pre-prepared holes available for securing boxes in any of a variety of locations.

FIGS. 1-4show an adjustable electrical installation bracket10used for mounting any of a variety of electrical boxes12. The bracket10has a pair of bracket parts14and16that are in a telescoping arrangement, with the parts14and16fitting together and able to slide relative to each other in order to change the length of the bracket10. The bracket part14includes an ear24, and a pair of legs26and28that extend parallel to one another from one end of the ear24. The bracket part16similarly includes an ear34, and a pair of legs36and38extending parallel to one another from an end of the ear34. The legs26and28have respective rails40and42on a back face44of the bracket part14, and the legs36and38have respective rails46and48on a back face50of the bracket part15. When the bracket parts14and16are mechanically coupled together, the rails40and42nest in the rails46and48, maintaining mechanical connection between the bracket parts14and16.

The legs26,28,36, and38together constitute a body52of the bracket10, with the body52having a front face54and a back face56. The rails40,42,46, and48are on the back face56of the body52. Alternatively, the rails40,42,46, and48may be on the front face54.

The rails40,42,46, and48receive flange tabs of the electrical box12. Referring toFIG. 2, with the flange tabs within the rails40,42,46, and48allow a front part64of the electrical box12, such as an attached mud ring, to protrude through an opening66of the bracket10. The opening66is defined by and bordered by the ears24and34, in combination with the legs26,28,36, and38. So situated, the electrical box12is able to change position relative to the bracket10without being disengaged from the bracket10. This advantageously facilitates fine adjustment of the position of the electrical box12.

In the illustrated embodiments various types of electrical boxes12are mounted in the bracket10. The bracket10may be used for mounting a single electrical box12, for example as shown inFIGS. 1-3, or may be used for mounting multiple electrical boxes12, as shown inFIG. 4.

The rails40,42,46, and48are fold-over extensions of the legs26,28,36, and38. The rails40,42,46, and48may be folded in any of a variety of ways. In one embodiment the rails40,42,46, and48are curled around, as shown inFIG. 3for the rails40and46. The rails40and46have respective curved portions70and76that connect them to the legs26and36. The curved portions70and76end in respective flat extensions, such as the flat extension78shown inFIG. 3, that may be substantially parallel to the back faces44and50. The curvature of the curved portions70and76may be different, with the curved portion70have a smaller radius of curvature than the curved portion76, to allow the rail40to fit into and engage the rail46. As an alternative, the rails40,42,46, and48may be folded at angles to the back faces44and50, for example being folded at approximately a 45 degree angle to the back faces44and50.

The legs26,28,36, and38have series of holes88running along their lengths, spaced apart in the directions away from the ears24and34. When the bracket parts14and16are fitted together, the holes88form two sets of holes on opposite sides of the opening66, along the length of the bracket10. A top set90of the holes88is at the top of the bracket10, constituting the holes88in the legs26and36. A bottom set92of the holes88is at the bottom of the bracket10, constituting the holes88in the legs28and38. The sets90and92run parallel to each other, with the holes88spaced so that adjacent holes are an even predetermined distance from each other, with adjacent of the holes88about 3.2 mm (0.125 inches) apart, for example.

The holes88are used for receiving screws, such as the screws98, for securing the electrical box12to the bracket10. The holes88may be positioned on the legs26,28,36, and38such that the screws98are able to be engaged with the holes88without coming into contact with the extensions of the rails40,42,46, and48. In an overlap section100of the bracket10, where the legs26and36overlap, and where the legs28and38overlap, the brackets14and16may be adjusted relative to one another such that the holes88of the bracket parts14and16align. The screws98may be sheet metal screws that have threads that cut to some extent into the portions that surround that holes88that they are screwed into, allowing the screws98to remain fixed in place without use of additional hardware, such as nuts. Similarly, the screws98may cut into holes in the flange tabs of the electrical box12. The holes in the flange tabs may be substantially the same size as the holes88, or may be a different size. The screws98may also be used for securing the bracket parts14and16together in a desired configuration, such as at a desired length. As many screws98may be used as necessary. As an alternative to the screws98, other sorts of threaded fasteners may be used for a similar purpose. The screws98may come preinstalled in some of the holes88, for example in holes88at one or both ends of the hole sets90and92, which holes are unlikely to be used for mounting the electrical box12.

The ears24and34have features to aid in mounting the bracket10to studs, other structure, or other devices or objects. The ear24has a pair of tabs104that can be bent down by an end user to engage a side surface of a stud or other object. The ear24also has a number of mounting holes108, for receiving suitable fasteners, such as screws, for securing the bracket10to a stud or other object. One of the holes108is between the bendable tabs104, and the other holes108are located further from the opening66, near outer corners of the ear24.

The ear34has a pair of tabs114that are bent down, protruding from the back face50of the bracket part16, that facilitate positioning of the bracket10by pushing the tabs114against a stud or other object. The tabs114may be bent as part of the manufacturing process. Alternatively the tabs114may be configured to be bent by the end user, for example by hand or using a hand tool, such as a screwdriver. The ear34also has a mounting hole118for receiving a fastener, such as a threaded fastener like a sheet metal screw, for securing the ear34to a stud or other object.

With reference in particular toFIG. 1, the bracket10and the electrical box12may be installed as follows. First, with the bracket parts14and16already coupled together, the electrical box12is engaged with the rails40,42,46, and48. The bracket10may then be placed between a pair of studs150and152. The tabs114on the ear34may be bent down and pressed against a side surface of the stud152, with the bracket part14then extended relative to the bracket part16so that at least part of the ear24overlies the stud150. The ears24and34may then be connected to the studs150and152using suitable fasteners, such as sheet metal screws156.

The electrical box12may then be positioned as desired between the studs150and152, without a need to hold the electrical bracket10in place during the positioning. The close spacing of the holes88allows a large number of possible positions of the electrical box12between the studs150and152. This is an advantage in installations where precise placement of the electrical box12may be required. For instance, in hospitals it may be required that boxes for some equipment be positioned to an accuracy of 3.2 mm (0.125 inches). Once the box12is positioned where desired, the screws98(or other fasteners) may be used to secure the box12to the bracket10.

As shown inFIG. 4, some or all of the legs26,28,36, and38may have markings158on them, such as etched lines, to facilitate positioning of one or more of the electrical boxes in desired positions. The markings158may be spaced apart from one another by a set distance, for example being spaced apart by 6.4 mm (0.25 inches).

In the illustrated embodiment ofFIG. 2, the box12has a mud ring64that is part of the box12. This arrangement makes for an assembly that has a minimum of parts that need to be manipulated. For example the installation does not require a separate mud ring that is placed on a front side of a bracket, and is secured to a box on the back side of the bracket, with the bracket sandwiched between the box and the mud ring. Details regarding the box12shown inFIG. 2may be found in commonly-owned U.S. patent application Ser. No. 13/347,033, “Backless Electrical Box and Method of Making,” filed Jan. 10, 2012, and incorporated by reference in its entirety. The box12shown inFIG. 2has different distances between its flange tabs in one direction160, than in an orthogonal direction162. The first flange tab spacing in the direction160is configured for use with the bracket10, while the other flange tab spacing in the direction162is for use with an alternate embodiment bracket that is described further below.

The box12alternatively may have any of a variety of other suitable configurations that allow it to engage the bracket10for mounting. Although there are advantages to using a backless box with a built-in mud ring, arrangements with a separate mud ring may be used instead.

The bracket10may be made of any of a variety of suitable materials, for example sheet steel, another metal, or plastic. Suitable fabrication steps, such as stamping, cutting, and bending, may be used to manufacture the bracket10.

The bracket10may be used to install the box12in a ceiling, between ceiling beams. The bracket10may be used in any of a variety of other situations or configurations, especially where the length of the bracket10(the dimension from the ear24to the ear34) is in a primarily horizontal direction.

FIGS. 5 and 6show an alternate embodiment bracket210that is used for mounting the electrical box12, with the bracket210oriented vertically. The bracket210has rails220and222on its back face224. The rails220and222run parallel to one another, on opposite sides of a central opening226. The rails220and222are inward-bent portions of flanges228and230of legs234and236that flank the opening226, with the rails220and222on opposite sides of the opening226. Curved portions238and240are between the rails220and222, and the rest of the flanges228and230. The curved portions238and240provide a smooth transition to the rails220and222, and also aid in facilitating engagement of the flange tabs of the electrical box12with the rails220and222.

The electrical box12may be engaged with the bracket210by sliding the flange tabs of the box12into engagement with the rails220and222. The flange tabs with the spacing162are used for engaging the rails220and222. Thus the rails220and222have a different spacing than the rails40,42,46, and48(FIG. 4) of the bracket10(FIG. 1). In the illustrated embodiment the rails220and222are spaced further apart than the rails40,42,46, and48.

The bracket210has a bottom310with a number of features used for mounting and stabilizing the bracket210. A pair of bottom flange tabs242are on opposite sides of the bottom310, and may be used for securing the bracket210to a channel or bracket243, as shown inFIG. 7. The bottom310also has a bottom edge flange244that is bent at an angle relative to a body246of the bracket210, toward the back face224of the bracket210. For example the bottom edge flange244may be at a right angle to the body246. The bottom edge flange244may have a rounded cutout248(FIG. 6) for letting wires, cables, conduits, tubing, or other runs, pass through the bottom edge flange244.

The bottom310also has a series of bendable tabs250,252, and254. The side tabs250and254may be bent inward, toward the back face224, in the same direction as the bottom edge flange244. The side tabs250and254also may be used to engage the bottom of structure, such as a footer256(FIG. 7), and may have holes in them, used to receive fasteners, such as sheet metal screws, for securing the tabs250and254to structure such as the footer256. The middle tab252may be folded down in the opposite direction, away from the bottom edge flange244, and in the direction of a front face258of the bracket210. The folded-down middle tab252acts as a foot to help provide stability to the bracket210.

The bracket210has a top260that also has a series of features for mounting. The top260has a pair of top flange tabs262on opposite sides of the top260. The top flange tabs262may be used for securing the bracket210to structure or another object, for example using fasteners such as sheet metal screws to secure the bracket210to the channel243, as shown inFIG. 7. Other fastener holes264may be used for receiving various types of fasteners, such as screws or nails.

A top flange270may be initially located in the opening226that is bordered on either side by legs234and236. The top flange270may be an angled flange, having a pair of parts278and280that are at right angles to each other. The proximal flange part278, which is bendable connected to a bottom edge284of the top260, may have a bendable tab288. The distal flange part280may have a series of openings290, configured to receive and clamp various sizes of runs of conduit, for example. Various sized punch-out portions may surround parts of the openings, with removal of one or more of the parts increasing the size of the openings290, allowing the openings290to be configured by an end user to receive different sizes of conduits, or other objects. The tab288may be located so that it can operate to secure the top flange270to the rest of the top260, as shown inFIG. 7.

Alternatively the top flange270may be bent as shown inFIG. 5. In this configuration the distal flange part280is used to support the back of the electrical box12.

The legs234and236each have various holes300, for securing the electrical box12when the box12is engaged with the rails220and222. Screws, such as sheet metal screws, may be screwed into the holes300and/or holes in the box's flange tabs, to hold the electrical box12(or multiple electrical boxes) in place relative to the bracket210. The leg234also has a series of bendable tabs304that may be bent down to hold one or more boxes in place, for example to position the box(es) temporarily before they are permanently secured using fasteners in the holes300. The legs234and236include respective locking tabs312and314, at a location just below the bottom of the rails220and222. The locking tabs312and314may be bent downward by an end user to prevent the electrical box(es)12from sliding down and disengaging from the rails220and222.

The legs234and236may have markings330on them. The markings330may be etched lines, and may indicate where electrical boxes or other equipment are to be positioned in order to have the boxes at specified heights above the footer256(or the floor).

FIG. 8shows an alternate installation for using the bracket210. One electrical box12is engaged with the rails220and222, and is located in the central opening between the legs234and236. The other box342is outside of the central opening226, attached to the leg236. The bracket210thus may be used to secure the boxes12and342in a side-by-side configuration.

FIG. 9shows another installation using the bracket210. A strip350runs between a pair of vertical channels or studs352and354. The strip350supports the top of bracket210by running behind the flange270. Specifically the strip350runs behind and supports the proximal flange part278. The strip350may be attached to the proximal flange part278. The strip350has holes360in it, for receiving fasteners such as mounting screws362for securing the strip350to the channels or studs352and354.

As noted above, the brackets10and210have many advantages over prior devices for mounting electrical boxes. The brackets10and210allow flexibility and accuracy in mounting any of a variety of electrical boxes in any of a variety of positions or configurations. Installations with the brackets10and210may also be performed efficiently, saving time in installation processes, and allowing installation with a minimum of separate parts to be manipulated.