Abstract:
The invention pertains to an electrical box assembly having a support structure for use in securing electrical enclosures, housings or boxes or the like to a stud. Upon insertion of the stud into a stud-receiving cavity of the assembly, a movable tab is pivoted to press one or more prongs into engagement with the stud. Pivoting of the tab may continue until the tab is locked in place whereupon the electrical enclosure is secured to the stud in compliance with code requirements without the need for such secondary operations as driving a separate fastener into the stud; the box now being secured with sufficient rigidity to satisfy local code enforcement.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/688,256 filed on Jun. 7, 2005. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention generally relates to an electrical enclosure, housing or assembly supported from a stud and, more particularly, to a bracket affixed to the enclosure or assembly that once applied to the stud, requires no further operation, installation or hardware to meet industry codes.  
       BACKGROUND OF THE INVENTION  
       [0003]     Electrical enclosures, frames, housings, boxes or the like are quite common and are extensively used to support fixtures to which high and low voltage wires are terminated. Examples of such fixtures are switches, duplex receptacles, GFCIs, telephone jacks, cable connections and other power or communication devices. Such enclosures supporting these fixtures are not free-standing and thus require support within the building structure if they are to be installed in accordance with local or national industry codes. These codes often specify a certain loading or series of forces the enclosure must withstand after being installed.  
         [0004]     Perhaps the most common way of supporting such devices is via nails or screws inserted through openings in the device before being driven into a stud of the building. Other methods of securing electrical enclosures to a building include a separate elongated metal bracket that spans between adjacent studs or support members, the enclosure then being bolted or screwed to the bracket. Another method involves a metal or plastic bracket affixed to the box that is pushed onto or against a stud and then subsequently fastened in place via nails or screws.  
         [0005]     As quick and simple as the above may appear, the operation of driving or fastening the nail or screw is still a secondary operation that must be completed after the device is initially positioned. This secondary operation requires time, some more than others, thus prolonging the process of securing the device to the stud in a manner that will comply with local requirements. Such secondary operations also reduce the number of boxes that can be installed in a given period of time.  
         [0006]     To ease installation when it is known that a nail or screw is to be used, electrical outlet enclosures are oftentimes manufactured with the nail or screw being held captive on the device prior to installation. Thus, to cut down on the number of secondary steps required, the user need only drive the nail or screw home after the enclosure is positioned against the stud. However, care has to be taken to insure that the step of screwing or nailing does not move the enclosure out of position. Also, care has to be taken that this additional fastening hardware is not dropped or lost. Furthermore, the user has to be mindful of how the enclosure is held during the driving operation so that the step of swinging a hammer or installing a screw does not inadvertently result in personal injury or damage to the enclosure. Additionally, once the fastener is embedded into the stud, it becomes quite difficult to remove the enclosure or change its location if such becomes necessary.  
         [0007]     Thus, it becomes desirable to avoid these secondary securement steps so that more devices can be installed in the same period of time. It is also desirable to dispense with these separate fasteners or screws as this only adds cost and another assembly step in the manufacture of the final product. Furthermore, such fasteners can be lost. Safety is also a factor as one injury can result in considerable and quite unexpected cost and delay. Another desirable feature is to have the device secured to the stud immediately after initial installation with no further operation required by the installer. Yet another desirable feature is a low cost box that can be secured as above while still complying with local codes and ordinances. These and other objects and advantages of this invention are described in greater detail below.  
       SUMMARY OF THE INVENTION  
       [0008]     The invention pertains to an electrical box assembly having a support structure for use in securing electrical enclosures, housings or boxes or the like to a stud. Upon insertion of the stud into a stud-receiving cavity of the assembly, a movable tab is pivoted to press one or more prongs into engagement with the stud. Pivoting of the tab may continue until the tab is locked in place whereupon the electrical enclosure is secured to the stud in compliance with code requirements without the need for such secondary operations as driving a separate fastener into the stud; the box now being secured with sufficient rigidity to satisfy local code enforcement.  
         [0009]     Various aspects of the assembly relate to supporting an electrical fixture from a stud. For example, according to one aspect of the invention, an electrical box assembly includes an electrical enclosure, a bracket affixed to the enclosure, the bracket defining a stud-receiving cavity extending along an edge of the enclosure, and a tab extending from the bracket and being movable between a stud-receiving position and a stud-securing position. The tab is adapted to include at least one prong that extends into the stud-receiving cavity when the tab is in the stud-securing position whereupon insertion of a stud into the cavity and movement of the tab to the stud-securing position engages the prong and thereby secures the enclosure to the stud.  
         [0010]     In another aspect of the invention, a support structure for an electrical enclosure includes a bracket extending from a first surface of an electrical enclosure, the bracket having a first generally planar surface, a flange extending from the bracket, the flange having a generally planar surface defining a stud receiving cavity, and a tab for securing a stud in the stud-receiving cavity. The tab being movable between a stud-receiving position and a stud-securing position and adapted to include at least one prong that extends into the stud-receiving cavity when the tab is in the stud-securing position whereupon insertion of a stud into the cavity and movement of the tab to the stud-securing position engages the prong and thereby secures the enclosure to the stud.  
         [0011]     Additional features and advantages will be readily apparent from the following detailed description, the accompanying drawings and the claims. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]      FIG. 1  is a front perspective view of the invention.  
         [0013]      FIG. 2  is a rear perspective view of the invention.  
         [0014]      FIG. 3  is a side perspective view of the invention shown secured to a stud. 
     
    
       [0015]     Like reference symbols in the various drawings indicate like elements.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0016]     Referring now to  FIG. 1 , an electrical box assembly  10  is shown comprising an enclosure, i.e., a box  12 , and a support structure, i.e., a bracket  14 . It should be understood from the outset that the box  12  can comprise a single or a multiple gang outlet box. Also, box  12  can comprise a combo box or enclosure of the type shown in U.S. Pat. No. 6,727,428 wherein both a power connection and a low voltage connection can be made. Furthermore, the box  12  can comprise simply a low voltage frame similar to the low voltage frame shown and described in the above U.S. patent. Other structures are equally likely for the box  12  and are meant to be included herein.  
         [0017]     Referring now to  FIG. 2 , in one preferred embodiment, the bracket  14  extends from a side  16  of the box  12  and defines a stud-receiving cavity  18 . The bracket  14  is sized to allow a stud  20  to be inserted within the stud-receiving cavity  18 . As best shown in  FIG. 2 , the stud-receiving cavity  18  is fully defined by the bracket  14 . The present invention, however, is not limited to such an embodiment. For example, in an alternative preferred embodiment, the side  16  of the box  12  may define one side of the stud-receiving cavity  18 .  
         [0018]     Referring back to  FIG. 1 , the bracket  14  is preferably secured to one side of the box  12  and is recessed a distance D from an edge  13  so as to accommodate drywall or other wall covering that may surround the box  12 . In one preferred embodiment, the bracket  14  has a generally planar top surface  24  to facilitate installation of drywall thereon.  
         [0019]     In one preferred embodiment, box assembly  10  includes a drywall support  22  on the side of the box opposite the bracket  14 . Support  22  is also spaced a distance D from edge  13  and also serves to brace drywall material (not shown) adjacent the front opening of the box  12 .  
         [0020]     Referring back to  FIG. 2 , forming a portion of the bracket  14  are a first flange  26  and a second flange  28  that extend perpendicular from the planar top surface  24 . The flanges  26 ,  28  extend generally parallel to each other and to the side  16  of the box  12 . As described previously, in one preferred embodiment, the flanges  26 ,  28  and the generally planar surface  24  of the bracket  14  define the stud-receiving cavity  18 . Also, as described previously, an alternative embodiment of the present invention may eliminate the first flange  26  and form the stud-receiving cavity using the side  16  of the box  12 . The rigidity of the interconnection between the flange  28  and the planar surface  24  may be further enhanced by employing stiffeners  42 .  
         [0021]     As shown in  FIGS. 2 and 3 , in one preferred embodiment, the second flange  28  is configured with a pivotal tab  30  that pivots about a hinge  32 . The hinge  32  may be formed from a thin strip of the same material from which the box assembly  10  is constructed. Preferably, the tab  30  is located along a mid-region of the bracket  14  and is designed for easy operation by the user.  
         [0022]     Referring back to  FIG. 1 , the upper surface of the tab  30  includes indicia  34  that aids the user in the operation of the assembly  10  and instructs the user to press or pivot the tab  30  about the hinge  32 . Preferably, the upper surface of the tab  30  includes one or more ribs  36  that allow for better gripping of the tab  30  by the user.  
         [0023]     The underside of the tab  30  is shown in  FIG. 2  and is configured with one or more prongs  38  that extend from the tab  30  and into the stud-receiving cavity  18  upon pivoting the tab  30  about the hinge  32 . Of course, it will be appreciated by one skilled in the art that the actual number and type of prongs  38  configured on the tab  30  may be varied. For example, teeth, nails, rivets, and pins may be used as prongs.  
         [0024]     The prongs  38  of the present invention are adapted to extend through respective openings  40  in the flange  28  and to engage and bias against a stud  20  upon pivoting the tab  30  from a stud-receiving position to a stud-securing position.  FIGS. 1 and 2  show the tab  30  in the stud-receiving position and  FIG. 3  shows the tab  30  in the stud-securing position. In one preferred embodiment, the prongs  38  are caused to bite into the stud  20  upon movement of the tab  30  to the stud-securing position. As shown in  FIG. 3 , upon insertion of the stud  20  into the stud-receiving cavity  18  and movement of the tab  30  to the stud-securing position, the prongs  38  engage the stud and thereby secures the assembly to the stud.  
         [0025]     The underside of the tab  30  is configured with a locking member  44  that latches with a corresponding catch  46  in the flange  28  to further secure the tab  30  in the stud-securing position. Of course, if desired, the locking member  44  may be formed in the flange  28  and the catch  46  may be formed in the tab  30 . The locking member  44  and catch  46  may vary from that shown in the drawings, and other fastening techniques for further securing the tab  30  in the stud-securing position may be used.  
         [0026]     In one preferred embodiment, referring to  FIG. 2 , the first flange  26  includes one or more teeth  48  that extend into the stud-receiving cavity  18 . The one or more teeth  48  are configured to grip the stud  20  from the opposite side of the tab  30  upon movement of the tab  30  to the stud-securing position. As a result, the stud  20  is engaged by both the first and second flanges  26 ,  28 , respectively. The amount by which prongs  38  and teeth  48  extend into the stud receiving cavity  18  is a matter of design choice with such factors as the force required to fully lock the tab  30  in the stud-securing position being one item to be considered in that determination.  
         [0027]     In one preferred embodiment, the assembly  10  is molded using a conventional plastic material. Preferably, openings  50  are provided to allow the assembly  10  to be removed from the mold. Likewise, other methods of manufacture may be employed to create the assembly  10  other than molding. For example, a metal assembly or a combination of metal and plastic (i.e., two or more pieces) may be used to form the assembly  10 .  
         [0028]     The box assembly  10  may also include an alignment guide  52  that assists a user in positioning the stud  20  in the stud-receiving cavity  18 . Various types of alignment guides may be configured for the box assembly  10 . For example, the alignment guide  52  can take the form of a line, a marker, a slot, or an opening on the generally planar surface  24  of the bracket  14 .  
         [0029]     In operation, a user will note the location of where the box assembly  10  is to be secured to the stud  20  so that it may be properly placed thereon without the need for re-alignment once installed. Typically, prior to installation of the box assembly  10 , the stud  20  is marked not only as to the height of the box  12  on the stud  20 , but also whether the box  12  is to be a single gang box, a multi-gang box, a combination box supporting both power and low voltage fixtures or simply a low voltage frame. Once the location and type of box assembly  10  is established, the user, using the alignment guide  52 , installs the box assembly  10  by inserting the stud  20  within the stud receiving cavity  18 . Once fully inserted, the user then pivots the tab  30  to the stud-securing position to force the one or more prongs  38  against a side of the stud  20 . Pivoting of the tab  30  to the stud-securing position also embeds the one or more teeth  48  into the opposite side of the stud  20 . The pivoting of the tab  30  may continue until the locking member  44  engages the catch  46 . Once the tab  30  is locked in place, the resulting bias or pinching applied to the stud  20  adequately supports the box  12  so as to be in compliance with local and national code requirements.  
         [0030]     Those skilled in the art will appreciate that several benefits result from the present design. The user no longer needs to perform additional installation or fastening steps since the resulting bias or pinching of the stud  20  occurs automatically upon pivoting of the tab  30 . This results in increased user productivity as time needed to install secondary fasteners into the stud  20  can instead be used to install additional box assemblies  10 . Furthermore, no nailing or screwing is required to bring the box  12  in compliance with local or national code with respect to load bearing.  
         [0031]     Although preferred embodiments of the present invention have been described herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments and that various other changes and modifications may be affected herein by one skilled in the art without departing from the scope or spirit of the invention, and that it is intended to claim all such changes and modifications that fall within the scope of the invention.