Electrical device mounting assembly for angled mounting of high and low voltage components

An electrical device mounting assembly for recessed mounting of high and low voltage components in order to provide electrical power and low voltage signals to a television or home entertainment center is provided. Mounting surfaces are provided within the mounting assembly to recess electrical components therein and behind the wall surface. The assembly includes a mounting frame for receipt of mounting devices such as high voltage boxes and low voltage mounting plates. The mounting devices are secured at an angle with respect to the mounting frame, thereby minimizing the depth of the mounting frame while providing sufficient space for recessing plug ends of electrical cords and terminal ends of signal cables within the wall. The electrical device mounting assembly provides a recessed area on a wall for mounting all the various electrical and signal hookups for a television or home entertainment system.

FIELD OF THE INVENTION

This invention relates to electrical box assemblies for mounting components for high and low voltage devices and specifically to an electrical device mounting assembly that can be easily installed on an interior wall of a building and provide high and low voltage components connections to a television, computer, or home stereo system.

BACKGROUND OF THE INVENTION

With the proliferation of high definition televisions and various auxiliary devices, such as digital videodisc players, game stations, and surround sound systems, there is a need to manage the connections between these devices to ensure there is adequate power and also to manage the myriad of cables and cords that accompany such systems. Additionally, many electrical boxes for both high and low voltage components mount the components flush with the wall, which makes the plugs or connectors that mate with the wall-mounted components protrude from the wall, thereby making it difficult to mount an electrical device such as a television close to the wall. Electrical plugs or cords that extend from the wall are also susceptible to damage, such as from vacuum cleaners or other household hazards which may brush against the plugs or cords.

What is needed therefore is an electrical device mounting assembly that provides connection points for both high and low voltage components, provides isolation of high voltage connections from low voltage connections, provides features for managing the plethora of cables and wiring associated with modern television systems, and recesses the end connector of cords or cables to protect the plug ends of cords or end connectors of cables from undesirable contact with household appliances or household occupants. Furthermore, for electrical mounting assemblies that recess the ends of electrical cords within the wall, it is desirable to minimize the depth of the mounting assemblies to minimize the size and cost of manufacturing such assemblies.

SUMMARY OF THE INVENTION

The invention is an electrical device mounting assembly that enables mounting of high and low voltage components in a single assembly for providing electrical supply and low voltage signals to a television or home entertainment center. The electrical device mounting assembly provides mounting locations for recessing various electrical components behind the wall surface to make them unobtrusive and out of the way. The mounting assembly includes a mounting frame for housing high voltage electrical boxes and low voltage mounting plates. The mounting frame enables mounting of the high voltage boxes and low voltage mounting plates at an angle with respect to the wall, thereby minimizing the depth of the mounting frame while providing sufficient space for recessing plug ends of electrical cords and terminal ends of signal cables within the wall. The low voltage mounting plates are capable of accepting standard jacks for broadband cable, direct TV, surround sound cabling, or phone systems. The electrical device mounting assembly enables easy consolidation of all the various electrical and signal hookups for TV or home entertainment systems.

OBJECTS AND ADVANTAGES

The electrical device mounting assembly of the present invention provides several advantages over the prior art, including:(1) Mounting surfaces are provided for mounting both high and low voltage components. An electrical box, integral with the box member of the assembly, is provided for housing and isolating high voltage components, such as a duplex receptacle to provide line voltage to a TV or other electrical device. Mounting surfaces are also provided for mounting several low voltage components, such as a coupling plate for a coaxial cable.(2) Mounting surfaces are at an angle with respect to the front of the electrical device mounting assembly thereby advantageously minimizing the depth of the mounting assembly.(3) The electrical device mounting assembly includes a mounting frame that extends within the wall, thereby recessing electrical components within the wall to render them unobtrusive and out of the way. Recessing the electrical components enables mounting the recipient electrical device, such as a television, substantially flush against the wall and also advantageously recesses the plug ends of cords or end connectors of cables within the wall surface.(4) The electrical device mounting assembly provides features for managing the plethora of cables and wiring associated with modern television systems thereby providing a clean installation that is unobtrusive and minimizes the amount of wires and cables running between the wall and the television, speaker system, or other components of a home entertainment system.

These and other objects and advantages of the present invention will be better understood by reading the following description along with reference to the drawings.

TABLE OF NOMENCLATURE

The following is a listing of part numbers used in the drawings along with a brief description:

Part NumberDescription20electrical device mounting assembly, first embodiment22mounting frame24low voltage mounting plate26high voltage box28trim plate30side wall32end wall34back wall35corner wall36aperture in back wall38open area40tab42cable opening44boss46front face of mounting frame48spacer50front face of spacer52slot54gap56enclosure of mounting frame58brace60second brace62raised area64first frame66second frame68corner wall of frame70first lip72mounting boss73mounting bore74second lip75frame opening76component connection point78component bore79component boss80back side of low voltage plate82filet84sidewall of electrical box86end wall of electrical box88electrical box enclosure90recessed area92knockout94stud96fastener98fastener99attachment arrangement100duplex receptacle102CATV connector plate104end flange106inner aperture108outer aperture110fastener112bore114opening in trim plate116mounting fastener120electrical device mounting assembly, second embodiment122trim plate124first end flange126second end flange130fastener132end of trim plate134electrical fitting or connectorΘ1angle of first brace with respect to front faceΘ2angle of second brace with respect to front faceΘ3angle of first frame with respect to second frameΘ4angle of first lip with respect to first frameΘ5angle of second lip with respect to second frameD1depth of mounting frameD2spacing between apertures in trim plate

DETAILED DESCRIPTION OF THE INVENTION

With reference toFIG. 1there is shown a first embodiment of an electrical device mounting assembly20according to the present invention. The electrical device mounting assembly20includes a mounting frame22, two mounting devices including a low voltage mounting plate24and a high voltage box26, and a trim plate28.

Referring toFIGS. 2-5, the mounting frame22has walls30and32including two side walls30and two end walls32, a back wall34extending over a portion of the rear of the mounting frame22at its center and two corner walls35. Several apertures36are provided in the back wall34. Two large open areas38are provided on either side of the partial back wall34and a plurality of tabs40are provided on the mounting frame22extending inward from the end walls32. The side walls30include cable openings42therein and the back wall34includes bosses44that are coincident with the apertures36in the back wall. The side walls30and end walls32of the mounting frame22terminate in a planar front face46. Integral spacers48extend outwards from the end walls32and each include a flat front face50that is planar with the front face46of the mounting frame22. The integral spacers48are preferably ½-inch in length and thereby enable an installer to rapidly and accurately orient the mounting frame22with respect to a stud (not shown) in a new work situation in order to properly allow the proper spacing for applying conventional ½-inch drywall over the stud. A plurality of slots52are provided in the side walls30and end walls32of the mounting frame22. The tabs40are offset from the corner walls35thereby creating a gap54there between. As shown inFIG. 4, the mounting frame22includes an enclosure56defined by the side walls30and end walls32and a plurality of braces58and second braces60extending from each of the side walls30into the enclosure56. Each brace58is at an angle of Θ1with respect to the front face46and each second brace60is at an angle of Θ2with respect to the front face46. As will be described herein, it is critical to the present invention that the braces58and second braces60are each at an angle with respect to the front face46of the mounting frame22as this will insure that multiple component housings (not shown) can be mounted within the mounting frame22while minimizing the depth of the mounting frame22with the depth of the mounting frame22being defined as the distance between the front face46and the back wall34and shown as distance D1inFIG. 5. Most preferably, the depth D1of the mounting frame22according to the present invention is 3.8-inches or less, which depth is kept to a minimum by orienting the mounting devices24and26at an angle with respect to the front face46of the mounting frame22. Thus, the mounting of the mounting devices24and26at the desired angle achieves the unexpected results of enabling the fitting of a substantial number of mounting devices24and26in a mounting assembly20that extends a relatively short distance into the wall while still providing space for recessing the installed electrical components and any connected electrical cord plugs. As shown inFIG. 4, the braces58and60are formed by substantially triangular-shaped raised areas62in the side walls30of the mounting frame22. The raised areas62extend from both the top and bottom side walls30and provide the bracing surfaces58and60thereon.

With reference toFIGS. 6-8there is shown a low voltage mounting plate24that may form a portion of an electrical device mounting assembly according to the present invention. The low voltage mounting plate24includes a first frame64and a second frame66integral with one another at a corner wall68. The frames64and66are at an angle Θ3with respect to one another, which angle is preferably between 60 and 120 degrees and more preferably is 90 degrees, as depicted inFIG. 8. A first lip70extends at an angle Θ4from the first frame64and two mounting bosses72having mounting bores73therein extend from the first lip70. The second frame66also includes a second lip74extending there from with the second lip74extending at an angle Θ5from the second frame66. When the angle Θ3of the first frame64with respect to the second frame66is 90 degrees, the angle Θ4of the first lip70with respect to the first frame64is preferably 60 degrees and the angle Θ5of the second lip74with respect to the second frame66is preferably 30 degrees. The frames include frame openings75therein. Component connection points76extend into the frame openings75and include component bores78therein. The component connection points76include component bosses79extending from the back side80of the low voltage mounting plate24. A filet82is provided on the back side80of the low voltage mounting plate24extending between the frames64and66. When the low voltage mounting plate24is molded of plastic, the filet82is molded integrally with the low voltage mounting plate24and adds strength to the plate24at the point where the two frames64and66meet.

Referring toFIGS. 9-11, the high voltage box26includes many elements in common with the low voltage frame including a first frame64, second frame66, first lip70, second lip74, mounting bosses72, and component connection points76. The high voltage box26also includes a sidewall84and end walls86that cooperate with the second frame66to provide an electrical box enclosure88for accepting a high voltage electrical component (not shown) therein. A recessed area90is provided in each end wall86with a knockout92provided in each recessed area.

Reference is made toFIG. 12for an explanation of the operation of the electrical device mounting assembly20of the present invention. The electrical device mounting assembly20can be mounted to a wall and configured to hold two high voltage electrical boxes26, two low voltage mounting plates24, or one high voltage electrical box and one low voltage mounting plate. Thus, the electrical device mounting assembly can be configured to provide the proper amount of high and low voltage connection points depending on the needs of the situation. The particular arrangement depicted inFIG. 12depicts the electrical device mounting assembly20being configured to hold one high voltage electrical box26and one low voltage mounting plate24. The electrical device mounting assembly can be used for either new work, where sheetrock has not been installed over the studs, or old work situations. For an old work installation, a portion of the existing sheetrock is removed, typically between two studs, in the location where electrical services are required. One end of the electrical device mounting assembly20is typically secured to a stud94with fasteners96as shown.

After the electrical device mounting assembly20is secured at one end to the stud94, the assembly may be configured with two low voltage plates, two high voltage boxes, or one of each as desired. The high voltage box26and low voltage plate24can be installed into the electrical device mounting assembly20in any order by sliding the second lip74of the second frame66into the gaps54between the tabs40and corner wall68. The tabs40perform a critical function for the electrical device mounting assembly20as they enable an installer to rapidly configure the box with mounting devices24and26. The tabs40enable the mounting device24or26to easily seat in its proper place in the box assembly20as the tabs40enable the second lip74of the mounting device to slide into the gaps54formed by the tabs. Brace58and second brace60of mounting frame22brace and support the first frame64and second frame66respectively of the low voltage mounting plate24and high voltage box26when they are inserted into the mounting frame22and position the frames64and66at the desired angle with respect to the front face46of the mounting frame22. The mounting devices24and26are then secured to the mounting frame22by driving fasteners98through bosses72of mounting devices24and26into apertures36in the back wall34of mounting frame22. Fasteners98and bosses72therefore form an attachment arrangement99for securing the mounting devices24and26within the enclosure56of the mounting frame22. InFIG. 12, the high voltage box26is depicted with a duplex receptacle100installed therein and low voltage mounting plate24is depicted with two CATV connector plates102installed therein. The installation is completed by securing trim plate to the mounting frame22. Trim plate28includes two end flanges104with inner apertures106and outer apertures108therein. After the mounting frame22has been configured, fasteners110are driven into bores112in each corner of the front face46of the mounting frame22. The high and low voltage electrical components100and102will then be accessible through the opening114in trim plate28. After the trim plate28is secured to the mounting frame22, mounting fasteners116may be driven through the end flange104opposite the stud94to secure the opposing end of the electrical device mounting assembly20to the wall.

The completed electrical device mounting assembly20is depicted inFIG. 13. A low voltage mounting plate24has been installed in the right side of the assembly and a high voltage box26has been installed in the left side of the assembly. If an alternative arrangement of high and low voltage components is desired, the electrical device mounting assembly20may be configured with two high voltage boxes or with two low voltage mounting plates in lieu of one of each type electrical mounting device.

With reference toFIG. 14there is shown a second and preferred embodiment of an electrical device mounting assembly120. Mounting assembly120includes a mounting frame22, low voltage mounting plate24, and high voltage box26similar to the first embodiment. Mounting assembly120however includes a trim plate122in which the end flanges are nonsymmetrical including a first end flange124and a second end flange126. As shown inFIG. 14, the second end flange126is wider than the first end flange124. Trim plate122is sized to provide spacing equal to the standard spacing between studs. The spacing, denoted by D2inFIG. 14, is preferably 16-inches between the outer apertures108in the end flanges124and126to match the conventional center-to-center spacing between adjacent studs. The distance between sidewall30of mounting frame22and the outer aperture108of first end flange124is approximately half the width of a conventional stud94. Thus the mounting frame22can be jammed against a stud94and secured thereto with fasteners130driven through slots52in sidewall30into stud94. After the low voltage mounting plate24and high voltage box26are installed in the mounting frame22, trim plate122is secured to the mounting frame22by fasteners110. The opposite end132of the trim plate122is then secured to the opposite stud94with fasteners116. The second embodiment of the trim plate122according to the present invention therefore provides the ability to anchor the electrical device mounting assembly120to a stud94at both ends of the assembly, thereby providing an electrical device mounting assembly120that is secured at both ends to the wall.

As shown inFIG. 11, the high voltage box26may include a knockout or removable wall portion92therein in the recessed area90in one of the end walls86. The recessed area90in the sidewall86enables the use of electrical fittings or connectors such as the Black Button™ push-in fitting or connector134for connecting non-metallic cable to electrical boxes, which connector134is available from Arlington Industries of Scranton, Pa. The recessed area90permits use of the connectors134while preventing the connectors from projecting beyond the sidewall86and interfering with placement of the electrical device mounting assembly20in locations where space is tightly restricted.

The various portions of the electrical device mounting assembly20, including the mounting frame22, low voltage mounting plate24, high voltage box26, and trim plate28, may be constructed of metal or plastic. Most preferably, the mounting frame22, low voltage mounting plate24, high voltage box26, and trim plate28are each molded in one piece of plastic. Suitable plastics include polycarbonate and polyvinylchloride.

Having thus described the invention with reference to a preferred embodiment, it is to be understood that the invention is not so limited by the description herein but is defined as follows by the appended claims.