Precision box jig

Simplified, easy-to-use electrical utility box positioning jig assemblies (10, 54) are provided including an elongated, upright standard (16) having opposed, generally flat, front and rear surfaces, and a support (18, 56) positionable along the length of the standard (16) and operable to hold a utility box (12, 58) during attachment thereof to a structural member (44). In one embodiment, the support (18) is generally C-shaped and is designed to hold a utility box (12) commonly used in residential construction. Alternately, a C-shaped support (56) may be used having permanent magnets (80), in order to hold a metallic utility box (58) used in commercial construction. The standard (16) is designed for direct, face-to-face contact with a structural member (44), and is slotted to allow selective placement of the associated box holder (18, 56).

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is broadly concerned with precision jig assemblies especially designed for the accurate and repeatable positioning of electrical utility boxes on structural members (e.g., upright wooden or metal studs) during residential or commercial construction. More particularly, the invention is concerned with such jig assemblies of simplified design which can be used by both skilled and unskilled workmen to achieve proper utility box mounting throughout construction projects.

2. Description of the Prior Art

Devices have been proposed in the past to aid electricians in the placement of electrical utility boxes. However, these have been either unduly complex and difficult to use, or did not have a desirable degree of operational flexibility. For example, U.S. Pat. No. 5,361,509 describes an installation tool having a multiplicity of parts and consequent complexity of use. The tool of the '509 patent has a tubular support with a box-holding member together with separate height and depth adjustments and an alignment mechanism to ensure that an electrical box is properly located relative to a stud. Similarly, U.S. Pat No. 5,111,593 discloses an electrical utility box mounting device including a channel supporting a vertically shiftable, component which supports a utility box. This unit is relatively heavy and cumbersome and requires multiple positioning steps in use.

U.S. Pat. No. 5,921,522 describes yet another outlet box positioning assembly including an elongated support equipped with jaw and spacer bars for establishing the horizontal position of a utility box relative to a horizontal stringer. However, this device provides no height markings or other means of independently ascertaining a proper mounting height. U.S. Pat. No. 6,590,155 discloses a floor stand for mounting of an electrical utility box. However, this unit is not reusable and thus constitutes an added expense.

Other references of background interest includes U.S. Pat. Nos. 6,484,980 and 6,765,146.

SUMMARY OF THE INVENTION

The present invention overcomes the problems outlined above and provides a simplified electrical utility box positioning jig assembly broadly including an elongated standard presenting a pair of opposed, generally flat, front and rear surfaces, at least the front surface having a series of vertically spaced apart height measurement markings thereon. The assembly also includes a support configured to hold an electrical utility box, together with structure operatively coupling the support to the standard and permitting selective up and down movement of the support along the length of the standard and locking of the support at a selected height on the standard. Importantly, the rear surface of the standard is configured for direct, face-to-face contact with a structural member to which the box is to be attached when the box is held by the support.

In preferred forms, the standard includes spaced apart front and rear panels defining an elongated slot therebetween, the outer face of the front panel defining the front standard surface, and the outer face of the rear panel defining the rear standard surface. The front and rear standard surfaces are provided with vertically spaced apart height markings permitting precise positioning of the box-holding support. The spaced apart height markings may be integrally formed in the panel faces or may be in the form of a label that is permanently adhered thereto. Also, this design permits alternate use of the jig assembly for box mounting on either side of a structural upright member.

The box-holding support preferably has an elongated, threaded bolt which extends through the standard slot, and uses conventional fastening hardware to clamp the support in place against the standard. The support may be designed to receive a utility box and frictionally hold it in place, or alternately the support may have magnets serving to magnetically adhere a metallic box to the support.

During use of the positioning jigs of the invention, the box-holding support is first shifted to a selected position along the length of the standard, and is locked in place at such position. A utility box is then coupled with the support and the assembly is located adjacent a structural member with the rear surface of the standard in direct face-to-face contact with the structural member. The utility box is then attached to the structural member and the jig assembly is removed. This operation may be repeated as necessary, in order to properly position all of the utility boxes at substantially the same height throughout the construction site.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Turning now to the drawings, and particularlyFIGS. 1-4, a positioning jig assembly10is illustrated, which is especially designed for installation of electrical utility boxes12onto structural members such as upright studs14in an accurate, and repeatable fashion. Broadly speaking, the assembly10includes an upright standard16, a generally C-shaped support18and coupling structure20for coupling the support18to standard16.

In more detail, the standard16is made up of an elongated front panel22having a front surface24provided with a series of spaced apart (e.g., at ½-inch increments), horizontal height markings26, and a substantially identical rear panel28presenting rear surface30also having spaced apart height markings32. As best illustrated inFIG. 3, the front and rear panels22and28are separated by means of internal spacers34and36, and by lowermost base38, thereby forming an elongated slot40extending along the length of the standard. As shown, the base38is somewhat triangular in shape so as to present a relatively wide floor-contacting bottom surface. The components of standard16are adhesively secured together, with the spacers34and36and base38sandwiched between the front and rear panels22,28.

The support18(seeFIG. 3a) includes an upright, central bight section42as well as upper and lower projecting arms44,46. The bight42has an elongated, substantially rectangular projection46sized to fit within slot40, and the arms44,46are spaced so as to receive and frictionally hold a utility box12(FIG. 1). The coupling structure20includes an elongated, threaded bolt48extending from bight42and of a length to extend fully through the slot40. A washer50and wing nut52are secured to the outer end of bolt48and engage the opposite face of standard16, as illustrated inFIGS. 1,2, and4. Preferably, the thickness of support18is substantially the same as the thickness of standard16so that the inner and outer surfaces of the support are essentially flush with the front and rear surfaces24,30of the standard16.

The use of assembly10is best illustrated inFIGS. 1 and 4. As a preliminary matter, the support18is located along the length of standard16by loosening lock nut52and vertically shifting the support18to a desired height position; this is facilitated by virtue of the height markings26. Next, the assembly10is positioned adjacent a structural member, as illustrated inFIG. 1, with the rear surface30of rear panel28in direct, face-to-face contact with the facing edge of member14. At this point, a box12is loaded into the support18with the forward open face of the box12substantially flush with the outer surface of the support18. In this fashion, the outer face of the box12is located forwardly of the edge of member14, which is desired in residential construction. The assembly10is then finally positioned in close adjacency to member14, as best seen inFIG. 4. The box12is then permanently affixed to the member14, by screws, nails, or any other convenient fastener. The assembly10can then be removed leaving the box12in place. In alternative procedures, the box12may be loaded onto support18prior to positioning of the assembly10adjacent member14.

It will also be seen that the orientation of assembly10may be reversed, i.e, the front panel22may be placed adjacent the member14, leaving the rear panel28exposed. This is convenient inasmuch as the assembly10may be used with equal facility to mount a utility box on either face of member14.

FIGS. 5-7depict another positioning jig assembly54in accordance with the invention. The assembly54includes the identical standard16of the first embodiment, but has a modified support56designed to hold a metallic electrical utility box58commonly used in commercial construction. As shown inFIG. 5, such utility boxes commonly have outwardly projecting attachment screws58aas well as upper and lower projecting attachment flanges59.

In particular, the support56(FIG. 7) is made up of three interconnected generally C-shaped bodies, namely outer bodies60,62together with an internal body64. Each of the C-shaped bodies60-64is of similar construction and include an upright bight66,68, and70, as well as upper and lower projecting arms72,74, and76. The arms76of the central C-shaped body64are notched as at78and each holds a permanent magnet80. In addition, the central body64has a rearwardly-extending projection82which fits within slot40of standard16. An elongated, threaded bolt84extends from body64and is of a length to pass fully through slot40. A washer86and wing nut88are provided to secure the body56to standard16. It will be observed that the three C-shaped bodies60-64have pairs of aligned slots90and92provided in the upper and lower arms thereof. Finally, it will be seen (FIG. 8) that the overall thickness of support56is greater than the thickness of standard16.

The use of assembly54is similar to that previously described in connection with assembly10. In this case, however, the utility box58is magnetically coupled to support56by virtue of the presence of the upper and lower magnets80. Specifically, box58is first positioned by inserting the screws58ainto the slots90,92, thereby magnetically adhering the box58to the support56. The assembly54is the placed adjacent structural member14, with the outer surface of standard panel22or28in direct, face-to-face contact with the member14. Again referring toFIG. 4, it will be noted that the metallic box58is offset rearwardly from the forward edge surface of the member14, which is desired for commercial construction. Next, appropriate fasteners are passed through the connection flanges59in order to secure box58to member14, whereupon the assembly54may be removed, leaving the box58in place. Again, this operation may be repeated throughout a given construction to achieve uniform placement of a multitude of utility boxes.

The embodiments described herein are illustrative of the present invention and should not be seen as limiting the scope of the invention in any way.