Electrical box support

A support is provided for mounting an electrical box in an opening formed in a block. The support includes a planar body configured to be coupled to a first side wall of the electrical box. The body includes at least one side edge. The support further includes a flange coupled to the first side edge of the body and extends substantially perpendicular to a plane of the body. The flange is configured to contact an outer surface of the block and to orient an outer edge of the electrical box relative to the block. The support further includes a retention member that is coupled to the body. The retention member has an end. At least a portion of the retention member is movable from a first configuration to a second configuration in which the portion of the retention member is positioned away from the body and contacts the block.

BACKGROUND

The present disclosure relates to electrical boxes, and more specifically to a bracket for supporting an electrical box.

SUMMARY

During construction of a wall it is desirable to securely mount an electrical junction box so that the electrical junction box does not move or shift during construction of the wall or during use after completion of the structure. Numerous mounting devices have been proposed for permanently and/or temporarily mounting electrical boxes in the cavity of a wall during construction. Standard outlet boxes often require mechanical fasteners to secure the electrical box permanently in place to a wall stud or other support structure. The mechanical fasteners are usually positioned to orient the electrical box in the desired location so that the outer edge of the electrical box is flush with the outer face of the wall.

The mounting of electrical boxes in concrete structures generally requires a different mounting assembly for holding the electrical box in position while the wall is being formed. In addition, concrete building materials do not enable the use of fasteners that are used in wood walls and studs since nail, screws, and other fasteners cannot be easily driven into concrete. Hollow concrete blocks provide a particular difficulty in mounting electrical boxes since there are no surfaces that can readily accommodate fasteners.

One manner of mounting an electrical box may include providing a sheet metal form with various tabs that can hold the electrical box in position while the cement or mortar sets. These devices often require the device to be installed during construction of a wall and to be positioned between joints, which can interfere with the structural integrity of the joint. These devices also require the use of cement or mortar to hold the support in place.

In one aspect, a support is provided for mounting an electrical box in an opening formed in a block. The support includes a planar body configured to be coupled to a first side wall of the electrical box. The body has at least one side edge. The support further includes a flange coupled to the first side edge of the body and extends substantially perpendicular to a plane of the body. The flange is configured to contact an outer surface of the block and to orient an outer edge of the electrical box relative to the block. The support further includes a retention member coupled to the body. The retention member has an end. At least a portion of the retention member is movable from a first configuration to a second configuration in which the portion of the retention member is positioned away from the body and contacts the block.

In another aspect, an electrical box assembly includes an electrical box having a first side wall, a second side wall, and an open front positioned between the first side wall and the second side wall. The electrical box assembly further includes a support having a body with at least one side edge. The body is coupled to the first side wall of the electrical box. The support further includes a flange coupled to the side edge of the body. The flange extends substantially perpendicular to a plane of the body. The support further includes a retention member coupled to the body. The retention member has an end. At least a portion of the retention member is movable from a first configuration to a second configuration in which the retention member extends away from the body. The retention member is configured to contact an opposite side of a block from the flange.

In yet another aspect, a method is provided for mounting an electrical box in an opening of a block. The method includes positioning the electrical box and a support in the opening in the block, positioning a flange of the support against an outer surface of the block, and deforming a retention member of the support such that the retention member extends away from a planar body until the retention member contacts an edge of the block.

Other aspects of the application will become apparent by consideration of the detailed description and accompanying drawings.

DETAILED DESCRIPTION

Before any embodiments are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. Use of “including” and “comprising” and variations thereof as used herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Use of “consisting of” and variations thereof as used herein is meant to encompass only the items listed thereafter and equivalents thereof. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.

FIG. 1illustrates support members or supports10and an electrical box12. The supports10are attached to the electrical box12. The electrical box12can be a standard electrical box with standard dimensions and shape. In the illustrated embodiment, the electrical box12is a single gang box having a substantially rectangular configuration. In some embodiments, the electrical box is a multi-gang box.

With continued reference toFIG. 1, the electrical box12has a pair of side walls14, a pair of end walls16, a back wall17and an open front18defined by corresponding front edges of the side walls14and end walls16. In the embodiment shown, the electrical box12includes a mounting flange20extending inwardly from each end wall16. In the embodiment shown, the mounting flange20extends between the side walls14to form a lip projecting into the opening18in the electrical box. Each mounting flange20includes a screw hole22for receiving a mounting screw to attach an electrical device (e.g., a wall switch or receptacle—not shown) to the box. An electrical conduit (not shown) can be coupled to the electrical box12at any one of a plurality of knockout bosses or stamps23to supply wires to the electrical box12and the electrical device as known in the art. Although the electrical device is not shown, it is understood that the electrical device can be any suitable electrical wiring device as known in the art that is mounted to an electrical box (e.g., an outlet, a switch, etc.).

With reference toFIGS. 2-4, each support10includes a body24which is formed as a substantially planar bracket. The body24has a first longitudinal end26, an opposite second longitudinal end28, a front edge30, and a rear edge32. As shown inFIG. 1, the body24may be dimensioned to be coupled to and lie flat against the side wall14of the electrical box12. The body24includes a central aperture36that is defined by opposing top and bottom inner edges40,44, and opposing front and back inner edges48,52.

In some embodiments (not shown), the support10is coupled to the side wall14via at least one tab that extends from the front edge30of the body24. The tab has a substantially U-shape having a first end attached to the front edge30and a second end extending toward the second side edge32such that the tab is slid over the front edge30. The tab may be configured so that the space between the ends of the tab allow for a friction fit to the side wall14so as to grip the side wall14. The tab may have a hook that engages with the electrical box12to secure the support10to the electrical box12. The hook resists separation of the supports10from the electrical box12during installation and during use. The tab and corresponding hook are described in further detail in U.S. Application Publication No. 2015/0263499, which is incorporated herein by reference. In some embodiments, the support10is coupled to the side wall14by fasteners (e.g., screws) or adhesive. In some embodiments, the support10is welded to the side wall14. In some embodiments, the support10is formed integrally with the side wall14of the electrical box12.

In the illustrated embodiment, a pair of supports are coupled to the electrical box12, with each support10coupled to one side of the box12. The supports10include a first or right support10and a second or left support10′. Each of the right and left supports10,10′ is a mirror image of the other such that the front edge30of each support10,10′ is positioned proximate the front opening18when coupled to the left and right side walls14, respectively. For brevity's sake, only the right support10is described in detail below. In some embodiments, at least one of the supports10,10′ can be coupled to one or more end walls16or combinations of the end walls16and side walls14of the electrical box12.

With continued reference toFIGS. 2-4, the support10further includes a first flange54that extends outwardly from the front edge30of the body24to position the support10and the electrical box12relative to the outer surface80of the block74(FIG. 5). The first flange54includes a pair of legs56that are connected to the front edge30. The first flange54extends substantially perpendicular to the plane of the body24away from the opening18when the support10is coupled to the side wall14. In the illustrated embodiment, the first flange54has a longitudinal length less than a length of the body24defined between the opposing first and second longitudinal ends26,28and a width sufficient to contact the outer surface80of the block74to stabilize and orient the electrical box12.

The support10further includes a second flange58that extends from a front inner edge48within the central aperture36to position and center the support10and the electrical box horizontally within the opening12. The second flange58includes a pair of angled legs60that couple the second flange58to the front inner edge48of the body24. The second flange58extends at angle relative to the plane of the body24away from the opening18when the support10is coupled to the side wall14and is generally parallel to the first flange54. In the illustrated embodiment, the second flange58has a longitudinal length less than a length of the central aperture36defined between the top and bottom inner edges40,44. The second flange58also has a width sufficient to contact the outer wall78within the opening72to stabilize, orient, and center the electrical box12within the opening72. The angle of the second flange58relative to the body24for each of the supports10,10′ can be adjusted to center the electrical box12horizontally within the opening72.

In the illustrated embodiment, the support10is formed from sheet metal, and the flanges54,58may be formed by bending a portion of the sheet metal during manufacture or during installation of the support10in the block74. In some embodiments, the first flange54can be formed as a tab extending in the plane of the body24, or parallel to the plane of the body24. In some embodiments, the first flange54may be removable or separable from the body24of the support10. For example, once the electrical box12is installed and construction of the structure is complete, the first flange54can be separated from the support10. In some embodiments, the first flange54is connected to the support10by a frangible portion forming a break line so that the first flange54can be separated from the support10by bending along the break line.

With continued reference toFIGS. 2-4, the support10further includes a retention member62. The retention member62has a first end64and a second distal end66. The retention member62is connected at the first end64to the bottom inner edge44of the central aperture36of the body24of the support10and extends along a length of the retention member to the second distal end66generally parallel to the first flange54. In some embodiments, the retention member62may extend from the top inner edge40, the front inner edge48, or the back inner edge52of the central aperture36. In a first, initial (undeformed) configuration, the retention member62is entirely positioned within the central aperture36and lies in the plane of the body24.

The retention member62has a first longitudinal edge68adjacent the front inner edge48of the central aperture36and a second longitudinal edge70adjacent the back inner edge52of the central aperture36. The first longitudinal edge68is tapered away from the first flange54and toward the second longitudinal edge70from the first end64to the second end66. The second longitudinal edge70is parallel to the back inner edge52of the central aperture36. Accordingly, the second end66is narrower than the first end64. In some embodiments, both of the first and second longitudinal edges68,70may be tapered inwards toward each other, or they may be parallel to one another, such that the first and second ends64,66are generally the same width.

The retention member62is deformable along the length of the retention member62from the first configuration to a second, deformed or deflected configuration. In the first configuration the retention member62lies in the plane of the body24, as shown inFIG. 2. In the deflected configuration, the second end66of the retention member62is bent away from the body24so that at least the second end66of the retention member62is extended away from the body24, as shown inFIGS. 3-4.

In the illustrated embodiment, the retention member62has an elongated slot or aperture90adjacent the second end66. The slot90extends through the retention member62and may be engaged by a tool (e.g., a flathead screwdriver) to assist a user in bending the retention member62into the deflected configuration.

In the illustrated embodiment, the support10is a single piece unitary member. In particular, the support10is made from sheet steel that is cut and folded to form the various tabs and flanges. The steel has sufficient strength and resilience to secure the electrical box in the opening of the building block as discussed above, but is flexible enough to allow the retention member62to be manually deformed. In alternate embodiments, the support10can be made of other material such as a molded one-piece plastic material.

Each of the left and right supports10,10′ is attached to each of the corresponding side walls14of the electrical box12. In other embodiments, only one of the left and right supports10,10′ may be used depending on the location of the opening72in the block74, the dimensions of the opening72in the block74, and the shape of the hollow core76of the building block. The supports10,10′ may be attached to the side walls14by fasteners, friction fit clips, welding, adhesive, or any other method for securing the supports10,10′ to the side walls14. In some embodiments, the supports10,10′ may be integrally formed with the side walls14.

Referring now toFIG. 5, the supports10,10′ are configured to support the electrical box within an opening72cut or formed into a structure (e.g., a brick or a building block74) during construction of a wall. The building block74has a cavity forming a hollow core76with an outer wall78having an outer surface80and an inner surface82.

The opening72is formed in an edge of the block74along an edge such that the opening72has an open side86. The assembly of the supports10and the electrical box12slides into the opening72of the block74in a direction parallel to the front face80of the block74(i.e., in the direction of arrow84shown inFIG. 5) while both the retention members62(FIG. 6) are in the first (undeformed) configuration. Before sliding the assembly of the supports10and the electrical box12into the opening72of the second flanges58are each bent at an angle relative to the body24of each support10,10′ so that the second flanges58contact the outer wall78to center the electrical box12within the opening72. Mortar may be applied to the outer wall78within the opening72before and/or after sliding the assembly into the opening72so that the second flanges58are embedded in the mortar. During the installation, the first flange54is bent to contact the outer surface80of the block74(FIG. 5). The first flange54may be bent before or after the electrical box12and the support10are slid into position within the opening72.

Once in position, the second end66of the retention member62is manually bent away from the body24and downward so that the first longitudinal edge68contacts the inner surface82at an edge of the opening72in the deflected configuration (FIG. 7). This is repeated for the retention member62of each support10,10′ coupled to the side walls14. Accordingly, the outer wall78of the block74is frictionally engaged between the retention members62and the corresponding flanges60to secure the electrical box12in place.

Due to the taper of the first longitudinal edge68, the retention member62can securely engage various widths of the outer wall78by bending the retention member62until the first longitudinal edge68contacts the inner surface82at an edge of the opening72(i.e., the retention member62is bent more or less depending on the width of the outer wall78). In the deflected configuration, the retention members62secure the electrical box12in place during construction and during use of the electrical box12so as to prevent separation and movement of the electrical box12with respect to the block74. Continuing to bend the retention member62causes the first longitudinal edge68to act as a wedge to further secure the electrical box12in place within the opening72.

The retention member62may be fully deformed into position before or after sliding the electrical box and support assembly into place within the opening72. Alternatively, the retention member62may be partially deformed before being slid into place, and then fully deformed to securely engage the first longitudinal edge68of the retention member62with the inner surface82of the block80.

In some embodiments, mortar may be applied within the opening72around the electrical box12, such that the second flanges58are embedded within the mortar. The mortar may be applied before and/or after the assembly is positioned within the opening72of the block74. The mortar is then allowed to cure to secure the assembly of the electrical box12and the support10within the opening72. Once the mortar has cured, the first flange54of each support10may be separated from the support10. In some embodiments, the first flange54may be separated by bending along a frangible break line until the first flange54breaks away from the body24of the support10so that the open front18of the electrical box12is generally flush with the outer surface80of the block74.

FIGS. 8-11illustrate another support410for use with the electrical box12in accordance with another embodiment. The support410ofFIGS. 8-11may be used in place of the supports10,10′ ofFIGS. 1-7on the electrical box12. The manner of coupling the support410ofFIGS. 8-11to the electrical box12is substantially identical to that of the support10ofFIGS. 1-7. In addition, the structure of the support410ofFIGS. 8-11is similar to the structure of the support10ofFIGS. 1-7, and only differences are described in detail. Similar features are identified with like reference numerals plus400and are not described again in detail.

With reference toFIG. 9, the retention member462is connected to a center of the rear edge432of the body424by an intermediate or connecting portion504that extends perpendicularly from the rear edge432within the plane of the body424. The retention member462includes a first portion508and a second portion512that are mirror halves across the connecting portion504. Each of the first portion508and the second portion512has a first end520connected to the connecting portion504by two connecting legs516. Each of the first and second portions508,512extends along a length from the first end520to a second distal end524such that the first and second portions508,512generally extend away from each other in opposite directions along an axis A parallel to the rear edge432(FIG. 9). In some embodiments, the first and second portions508,512may extend at an angle with respect to the axis A.

Each of the first portion508and the second portion512has first and second longitudinal edges528,532that extend from the first ends520of each of the first and second portions508,512to the corresponding second ends524. The first longitudinal edges528are closer to the rear edge432of the body424than the second longitudinal edges532. The second longitudinal edges532are collinear and parallel to the rear edge432. Each of the first longitudinal edges528tapers toward the second longitudinal edges532from the first end520toward the second end524. Accordingly, the second end524of each of the first and second portions508,512is narrower than the first end520.

Each of the first and second portions508,512of the retention member462is independently deformable along the length of the retention member462. Each of the first and second portions508,512of the retention member462lies in the plane of the body424when in a first, initial (undeformed) configuration, as shown inFIGS. 8 and 9. Each of the first and second portions508,512may be independently bent from the first configuration into a second, deformed or deflected configuration. The second end524of the first portion508may be bent away from the body424so that the first portion508extends at an angle from the body424, while the second portion512remains in the plane of the body424, as shown inFIG. 10. Alternatively, the second end524of the second portion512may be bent away from the body424so that the second portion512extends at an angle from the body424, while the first portion508remains in the plane of the body424, as shown inFIG. 11. Accordingly, the support410can be used on either of the side walls14of the electrical box12. For example, the first portion508can be bent for the support410on the right side wall14(FIG. 10) and the second portion512can be bent for the support410on the left side wall14(FIG. 11). Therefore, only a single version of the support410is needed for both side walls14of the electrical box12. This reduces the number of different parts that need to be manufactured and prevents the user from making the mistake of coupling the support410to an improper side. The first portion508and the second portion512of the retention member462are separately deformable first and second retention members that may be deformed independently depending on the orientation of the support410(i.e., whether it is coupled to the right or left side wall14).

As best shown inFIG. 9, the connecting legs516are narrower than the adjacent connecting portion504and narrower than the first end520of each of the first and second portions508,512. A gap536is defined between the connecting portion504, the first end520, and the legs516. Accordingly, as force (e.g., a downward force along the axis A to the second end524) is applied to each of the first and second portions508,512bending occurs at the legs516.

In the illustrated embodiment, the second end524of each of the first and second portions508,512has a tab540that extends at an angle away from the retention member462. The tab540may be used to assist a user in bending the corresponding one of the first portion508and the second portion512of the retention member462into the deflected configuration. The user may simply push down on the tab540with their thumb or a tool to bend the first portion508or the second portion512.

In the illustrated embodiment, one support410is attached to each of the corresponding side walls14of the electrical box12. In other embodiments only one support10may be used with one of the side walls14depending on the location of the opening72in the block74, the dimensions of the opening72in the block74, and the shape of the hollow core76of the block74. The supports10may be attached to the side walls14by fasteners, friction fit clips, welding, adhesive, or any other method for securing the supports10to the side walls14. In some embodiments, the supports10may be integrally formed with the side walls14.

The assembly of the support410and the electrical box12is received in the opening72cut in the block74similar to the assembly of the support10and the electrical box12ofFIGS. 1-7. Once in place, the first flange454is bent to contact the outer surface80of the block74. In some embodiments, the first flange454is bent before being positioned within the opening72. The first portion508of the retention member462of the support410that is coupled to the right side wall14is manually deformed so that the second end66is bent downward and away from the body424into the deflected configuration. The first longitudinal edge528contacts the inner surface82of the block74(FIG. 10). Similarly, the second portion512of the retention member462of the support410that is coupled to the left side wall14is manually deformed so that the second end66is bent downward and away from the body424so that the first longitudinal edge528contacts the inner surface82of the block74(FIG. 11). Accordingly, the outer wall78of the block74is frictionally engaged between the first and second portions508,512of the retention members462and the corresponding flanges460of each of the supports410to secure the electrical box in place relative to the block74.

Due to the taper of the first longitudinal edge528, the first and second portions508,512of the retention member462can engage various widths of the outer wall78by bending the first or second portion508,512until the first longitudinal edge528contacts the inner surface82of the opening72(i.e., bending the first or second portion508,512more or less depending on the width of the outer wall78). In the deflected configurations each of the first and second portions508,512has enough resilient force to secure the electrical box12in place during construction of the wall and during use of the electrical box12. Continuing to bend the first or second portion508,512of the retention member462causes the first longitudinal edge528to act as a wedge to further secure the electrical box12in place within the opening72.

Each of the first and second portions508,512of each retention member462may be fully deformed into position before or after sliding the electrical box and support assembly into place within the opening72. Alternatively, one of the first and second portions508,512of the retention members462may be partially deformed before being slid into place, and then once in place, fully deformed to securely engage the first longitudinal edge528of the respective first and second portions508,512of the retention members462with the inner surface82of the block74.

In the embodiments shown inFIGS. 1-11, the supports10,410are attached directly to the side walls14of the electrical box12. In some embodiments the support10,410is coupled to an electrical box having an extension collar in substantially the same manner as in the embodiments ofFIGS. 1-11. The collar is attached to an electrical box having a dimension larger than the opening in the block. A cover plate extending from the base of the collar is attached to the open end of the electrical box. The collar may be dimensioned for supporting an electrical wiring device and may include inwardly extending flanges at an end wall for fixing the hooks of the support10,410to the open end of the collar.

In general, the supports mount an electrical box in an opening of a structure such as a wall. Each support includes a retention member that is manually deformed to a deflected position for retaining the electrical box in the opening. More particularly, the support secures the electrical box in an opening formed in a hollow core masonry block or an opening in a concrete wall.

Although aspects have been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects as described. Various features and advantages are set forth in the following claims.