Abstract:
Improvements in a bracket is disclosed for mounting an electrical box onto a mounting bar. An electrical box can be preinstalled onto the bracket and clamped onto the mounting bar using wings. Bendable tabs can be articulated to secure the bracket and onto a rail. Fasteners are used to secure an electrical junction box onto the bracket and an additional fastener secures the sub assembly to the rail. The tabs can be unbent for removal. An installer can secure the bracket and electrical box using a screw and adjust the position of the bracket on the mounting bar. The bracket provides a low profile assemble that allows the bracket to be installed between the inner surfaces of stud walls.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a continuation-in-part of applicant&#39;s co-pending application Ser. No. 14/712,834 filed May 14, 2015 the entire contents of which is hereby expressly incorporated by reference herein. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable 
       THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT 
       [0003]    Not Applicable 
       INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC 
       [0004]    Not Applicable 
       BACKGROUND OF THE INVENTION 
       [0005]    Field of the Invention 
         [0006]    This invention relates to improvements in an electrical box mounting bracket. More particularly, the present an electrical box mounting bracket connects between an electrical junction box and a rail and allows the electrical junction box to be installed and positioned or re-positioned along the rail without any tools. 
         [0007]    Description of Related Art Including Information Disclosed Under 37 Cfr 1.97 and 1.98 
         [0008]    A number of patents and or publications have been made to address these issues. Exemplary examples of patents and or publication that try to address this/these problem(s) are identified and discussed below. 
         [0009]    U.S. Pat. No. 3,182,805 issued May 11, 1965 to A. A. Foster Jr. et al., discloses a Telephone Office Mounting Plate. The mounting plate clamps to a pair of rails to allow the telephone plate to slide along the rails to mount the telephone box at any location along the rails. While this patent allows the telephone box to be mounted to the railing, the telephone box is not a standard junction box that can be moved along the railing system. 
         [0010]    U.S. Pat. Nos. 4,967,990 and 5,209,444 issued on Nov. 6, 1990 and May 11, 1993, respectively, both issued to Eric R. Rider disclose a Support for an Electrical box. Both of these patents use a bar that mounts between two studs. The bar has a plurality of holes where a junction box is screwed onto the bar using holes on the bar. While this patent allows for a junction box to be mounted onto various positions on the bar, the positions are finite and further the bar is a fixed length. This patent does not allow for different lengths between studs or for infinite positioning along the bar. 
         [0011]    U.S. Pat. No. 5,330,137 issued on Jul. 19, 1994 to John H. Olvia discloses an Apparatus and Methods for Mounting an Electrical Box between Studs in a Wall. This patent uses an open frame where a junction box is mounted with a faceplate through the open frame to an electrical box. The open frame has a fixed dimension between the studs and the connection between the faceplate and the junction box must be made through the frame. Both the faceplate and the junction box must be uniquely fabricated to operate with the frame. 
         [0012]    What is needed is an adjustable stud support rail with a bracket that is slidable secured to the bracket. The bracket further should allow for a junction box to the mounted to the bracket. The electrical box mounting bracket disclosed in this document provides the solution. 
       BRIEF SUMMARY OF THE INVENTION 
       [0013]    It is an object of the junction box bar bracket to clamp onto a rail or mounting bar and to be able to be adjustably positioned. A mounting bar typically has a channel shaped cross section with a plurality of fastening holes. Flanges on the ends of the mounting bar allow for installation onto wood or metal studs. The electrical box mounting bracket is comprised of at least two wings or tabs that are bendable to secure the bracket and junction box on a mounting bar. To move the bracket, securing screws are removed and the bracket can be slid along the rail. The tabs or ears can be re-bent to allow the bracket to be removed from the rail. An installer can thus also adjust the relative position of the bracket with the mounting bar. 
         [0014]    It is another object of the junction box bar bracket to preinstall an electrical box before installing onto a mounting bar. An electrical junction box is typically a metal enclosure where wiring is brought into the box with conduit. Electrical wires are typically connected to an outlet, switch, or device. In order to place the outlet, switch, or device in its desired location behind drywall, a mounting bar is used to secure the electrical box in place. The electrical box mounting bracket features a fastening hole and tail for securing the electrical box onto said bracket. The assembly of the electrical box and bracket can then be mounted onto the mounting bar in the desired position before permanently securing with screws. 
         [0015]    It is another object of the junction box bar bracket to be economical. A bracket that uses open and closed positions can be seen in U.S. Pat. No. 8,702,047. However, due to the orientation of the front and rear jaw, a larger piece of sheet metal is required. The electrical box mounting bracket uses wings that can be moved to an open or closed position oriented in the direction of the mounting bar. As a result, the electrical box mounting bracket is reduced in size while maintaining a secure and dependable installation. 
         [0016]    This reduces the cost and greatly increases the ease of storage. 
         [0017]    It is still another object of the junction box bar bracket for the bracket to be low profile. The low profile refers to the distance from the back of the mounting bar to a wall on the other side of the junction box. The stack dimension must fit within a standard wall thickness of about 3½ inches and this junction box bar bracket achieves the low, thin profile. 
         [0018]    Various objects, features, aspects, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
         [0019]      FIG. 1  shows a perspective rear view of the junction box bar bracket, junction box, bar bracket ready to install. 
           [0020]      FIG. 2  shows the junction box bar bracket set onto a bar bracket. 
           [0021]      FIG. 3  shows the junction box bar bracket on a bar bracket with the locking ears bent. 
           [0022]      FIG. 4  shows a detail view of the junction box bar bracket set onto a bar bracket. 
           [0023]      FIG. 5  shows a detail view of the junction box bar bracket on a bar bracket with the locking ears bent. 
           [0024]      FIG. 6  shows the junction box bar bracket. 
           [0025]      FIG. 7  shows the junction box bar bracket with an electrical junction box. 
           [0026]      FIG. 8  shows the junction box bar bracket with an electrical junction box secured to a mounting bar. 
           [0027]      FIG. 9  shows the junction box bar bracket in a first preferred embodiment. 
           [0028]      FIG. 10  shows the junction box bar bracket in a second preferred embodiment. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0029]      FIG. 1  shows a perspective rear view of the junction box bar bracket  20 , junction box  16  ready to install on a bar bracket  19  that is installed on studs  18 . This is a typical installation where the junction box bar bracket  20  can be installed to accept an outlet or a switch box. The junction box bar bracket  20  essentially wraps around the junction box  16 . This embodiment is configured to accept two outlets or switches. It is further contemplated that the junction box bar bracket  20  can be configured to accept a single outlet or switch, but can also be configured to accept more than two outlets, switches or combination thereof. While outlets or switches are described, the electrical box can also be used for phone, internet or other uses. The studs  18  and footer  17  are typical dimensions such as 2×4, 2×6 or other wood or metal studs. The overall stack height of the junction box bar bracket  20  and junction box must fit within the internal wall cavity of typically 3½ inches. 
         [0030]      FIG. 2  shows the junction box bar bracket  20  set onto a bar bracket  19  and  FIG. 3  shows the junction box bar bracket  20  on a bar bracket  19  with the locking ears  26  and  27  bent. The junction box bar bracket  20  is placed onto the bar bracket  19  where the junction box bar bracket  20  is initially held in place with the bar bracket  19  captured between a shelf  31  that is formed by the rear rib  22  from a back plate  21 . The junction box  16  is captured on the junction box bar bracket  20  by side supports  40  and  41  that is bent around ears  25  and  26 , and is hung on a hook  60 . The side supports  40  and  41  bend from the top of the back plate  21  and the bottom  23  of the back plate. A fastener  15  is further used to secure the junction box  16  onto the junction box bar bracket  20 . Gravity will generally hold the junction box bar bracket  20  with the secured junction box  16  on the bar bracket  19 . The back of the junction box bar bracket  20  has a plurality of locking ears  26  and  27  located on a lower portion of the back plate  21  of the junction box bar bracket  20 . 
         [0031]    One or both of these locking ears  25  and  26  can be independently or collectively bent to secure the sub assembly on the bar bracket  19 . When the locking ears  25  and  26  are bent (as shown in  FIG. 3 ), the junction box bar bracket  20  with (or without) a secured junction box  16  is not freely removable from the bar bracket  19 . The ends of the locking ears  25  and  26  have ear tips  27  and  28  that provide additional structural support to the bottom of the bar bracket  19 , and further reduces a sharp edge to the end(s) of the locking ears  25 ,  26 . The ears  25  and  26  a separated from the back plate  21  with voids  29  and  30 . These voids  29  and  30  provide for a reduction in the material for bending the ears  25  and  26 , and also can be used with a tool, such as a screw driver, that can be inserted into the voids for easier bending of the ears  25  and  26 . While a screwdriver or other tool can be used the ears  25  and  26  are bendable by hand. 
         [0032]    The sub assembly can then be slid and positioned on the bar bracket to the desired location. Additional fasteners can be installed through the junction box bar bracket  20  into the holes, or slots  45  and  46  (not shown in this figure) in the bar bracket  19  to prevent movement of the junction box bar bracket  20  and junction box  16  on the bar bracket  19 . The upper portion of the junction box bar bracket  20  includes additional support features for securing the junction box bar bracket  20 . 
         [0033]    The upper portion of the junction box bar bracket  20  has side supports  71  and  72 . The side supports extend from the back plate  21  to a top support  73  that has a plurality of holes  74  for securing conduit tubes to the top support  73  with fasteners to reduce movement of the conduit. The middle top of the back plate  21  has a notch  77  that identifies the center of the junction box bar bracket  20 . 
         [0034]      FIG. 4  shows a detail view of the junction box bar bracket  20  set onto a bar bracket  19  and  FIG. 5  shows a detail view of the junction box bar bracket  20  on a bar bracket  19  with the locking ears  26  and  27  bent  51 ,  52 . As previously described the junction box bar bracket  20  is placed onto the bar bracket  19  where the junction box bar bracket  20  is initially held on the bar bracket  19  where it is captured between a shelf  31  that is formed by the rear rib  22  from a back plate  21 . The junction box  16  is captured on the junction box bar bracket  20  by side supports  40  and  41  that is bent around ears  25  and  26 , and is hung on a hook or rear tab  60 . The side supports  40  and  41  bend from the top of the back plate  21  and the bottom  23  of the back plate. A fastener  15  is further used to secure the junction box  16  onto the junction box bar bracket  20 . The back  21  of the junction box bar bracket  20  has a plurality of locking ears  26  and  27  located on a lower portion of the back plate  21  of the junction box bar bracket  20 . 
         [0035]    These locking ears  25  and  26  can be independently bent  51 ,  52  to secure the junction box bar bracket  20  and junction box on the bar bracket  19 . When the locking ears  25  and  26  are bent  51 ,  52 , the junction box bar bracket  20  is not freely removable from the bar bracket  19 . The ends of the locking ears  25  and  26  have ear tips  27  and  28  that provide additional structural support to the bottom of the bar bracket  19 . The ears  25  and  26  a separated from the back plate  21  with voids  29  and  30 . These voids  29  and  30  provide for a reduction in the material for bending the ears  25  and  26 , and also can be used with a tool, such as a screw driver, that can be inserted into the voids  29  and  30  for easier bending of the ears  25  and  26 . Slots  44  provide clearance for the ears  25  and  26  to bend from the back plate  21 . 
         [0036]    The sub assembly can then be slid and positioned on the bar bracket to the desired location. Additional fasteners can be installed through the junction box bar bracket  20  into the holes, or slots  45  and  46  (not shown in this figure) in the bar bracket  19  to prevent movement of the junction box bar bracket  20  and junction box  16  on the bar bracket  19 . 
         [0037]      FIG. 6  shows the junction box bar bracket and  FIG. 7  shows the junction box bar bracket with an electrical junction box and  FIG. 8  shows the junction box bar bracket with an electrical junction box secured to a mounting bar. These figures show the progression of installation of the junction box bar bracket  20 . These figures show the front features with the junction box bar bracket  20 . In  FIG. 6  the junction box  16  has not been installed. The tab or hook  60  is shows in these figures where the tab or hook  60  extend towards or into a junction box  16 , shown in  FIG. 8 . The locking ears are bent about  FIG. 8  to secure the junction box bar bracket  20  onto the bar bracket  19 . In  FIG. 7  the electrical box  16  is installed on the junction box bar bracket  20  onto tab or hook  60  and is being secured with fastener  15 . 
         [0038]    In  FIG. 8  the combined junction box bar bracket  20  and junction box  16  is being secured onto the bar bracket  19 , the ears  27  are bent and then a fastener  14  locks the position of the junction box bar bracket  20  and the junction box  16  onto the bar bracket  19 . These figures show the fastening ears  42  and  43  with slots  45  and  46  where a fastener is inserted through one or both slots  45  and/or  46  and then the fastener is engaged into the bar bracket  19 , shown in  FIG. 8 . 
         [0039]      FIG. 9  shows the junction box bar bracket in a first preferred embodiment. This embodiment is the embodiment that is shown and described in the previous figures. While this embodiment is shown, and described, other embodiments are contemplated that provide a similar securing mechanism. 
         [0040]      FIG. 10  shows the junction box bar bracket in a second preferred embodiment. This embodiment the top portion of the bracket is not present. The remainder of the clamping and securing mechanism and features remain unchanged. 
         [0041]    Thus, specific embodiments of a junction box bar bracket have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims.