Abstract:
A clip for mounting an object such as an electrical box on a stud is provided which comprises a fist side portion for engaging a first surface of the stud; a second side portion for engaging a second surface of the stud; the second side portion including at least one box clip arm for securing the electrical box to the clip; and at least one support member extending between the electrical box and the second surface of the stud for substantially preventing flexing of the clip and inward movement of the electrical box when a force is applied generally inwardly of the electrical box.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority under 35 U.S.C. §119(e) to provisional patent application Ser. No. 60/132,576 filed May 5, 1999, entitled “Clip For Attachment To A Metal Or Wood Stud,” the entire disclosure of which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to the art of support clips and brackets and, more particularly, to such clips or brackets for mounting devices, equipment or the like on wall studs. In even greater particularity, the present invention is directed to a one-piece tip sheet metal clip for mounting electrical boxes and other objects on metal or wood wall studs, the clip including at least one support member which extends between the electrical box and the webbing of the stud to provide support for the box against inward flexing of the clip when force is applied inward of the box. 
     BACKGROUND OF THE INVENTION 
     In mounting electrical boxes or the like on wall studs, it is desirable to provide support to the electrical box to counter any flexing of the mounting means experienced as a result of inward force on the box. Some designs typically omit the extra needed support altogether. Some designs incorporate a looping design which causes the clip to be more flimsy. These drawbacks can be extremely frustrating when attempting to complete electrical connections in the field. Accordingly, in view of the foregoing drawbacks with currently available clips, an improved clip for mounting objects on a wall stud is needed to overcome difficulties in support during installation and to provide benefits of costs and reliability. 
     SUMMARY OF THE INVENTION 
     Among the several objects of the present invention may be noted the provision of an improved one-piece sheet metal clip for mounting electrical boxes and other objects on metal or wood wall studs which includes at least on support member extending between the electrical box and the webbing of the stud to provide support for the box against flexing of the clip when force is applied inward of the box; the provision of such a clip which is easy to handle; the provision of such clip which has added versatility in that it may be used in several different ways to secure electrical boxes or the like to wall studs; and the provision of such clip which is of economical manufacture. 
     It is also an object of the present invention to provide such a clip that is selectively mountable to either the open or closed side of a channel-shaped metal wall stud. 
     It is another object of the present invention to provide such a clip having stud gripping barbs or prongs in optimum location and spacings. 
     The clip of the present invention is particularly applicable in mounting electrical boxes and the like to the closed side of a channel-shaped metal wall stud. However, it will be appreciated that the invention has broader aspects, and that the clip can be used for mounting electrical boxes and the like to other types of studs. 
     In one embodiment of the present invention, a clip for mounting an object such as an electrical box on a stud is provided which comprises a first side portion for engaging a first surface of the stud; a second side portion for engaging a second surface of the stud wherein the second side portion also includes at least one box clip arm for securing the electrical box to the clip. The clip further includes at least one support member extending between the electrical box and the second surface of the stud for substantially preventing flexing of the clip and inward movement of the electrical box when a force is applied generally inwardly of the electrical box. The support member may project from a distal end of the second side portion of the clip toward the second surface of the stud and may further include a turned lip portion for engaging the second surface of the stud. Preferably, the clip includes a pair of support members extending between the electrical box and the second surface of the stud for substantially preventing flexing of the clip and inward movement of the electrical box when a force is applied generally inwardly of the electrical box. The first side portion includes a first pair of prongs having pointed tips for gripping the first surface of the stud. The second side portion includes a second pair of prongs having pointed tips for gripping the second surface of the stud. Preferably, the second side portion includes a pair of box clip arms for securing the electrical box to the clip. The pair of box clip arms and the second side portion cooperate to define a channel means for receiving a side wall of the electrical box. The stud may be comprised a metal stud and the clip may be attached to a closed side of the metal stud. 
     In another embodiment of the present invention, a clip for mounting an object such as an electrical box on a stud is provided which comprises a first side portion for engaging a first surface of the stud; a second side portion for engaging a second surface of the stud; the second side portion including at least one box clip arm for securing the electrical box to the clip; and support means extending between the electrical box and the second surface of the stud for substantially preventing flexing of the clip and inward movement of the electrical box when a force is applied generally inwardly of the electrical box. 
     In yet another embodiment of the present invention, a one-piece clip for mounting an object such as an electrical box on a metal stud of generally channel shape having a web, a pair of generally parallel flanges and inwardly turned lips on the flanges, is provided comprising a first side portion for engaging one of the lips for securement of the clip to the stud; a second side portion for engaging the web of the stud for securement of the clip to the stud; the second side portion including at least one box clip arm for securing the electrical box to the clip; and at least one support member extending between a side wall of the electrical box and the web of the stud for substantially preventing flexing of the clip and inward movement of the electrical box when a force is applied generally inwardly of the electrical box. The support member may project from a distal end of the second side portion of the clip toward the web of the stud. The support member may also include a turned lip portion for engaging the web of the stud when the force is applied to the electrical box. Preferably, the clip includes a pair of support members extending between the side wall of the electrical box and the web of said stud. The second side portion preferably includes a pair of box clip arms for securing the electrical box to the clip. The pair of box clip arms and the second side portion cooperate to define a channel means for receiving the side wall of the electrical box wherein the clip is preferably attached to a closed side of the metal stud. 
     These and other objects, features, and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In order to more fully understand the manner in which the above-recited and other advantages and objects of the invention are obtained, a more particular description of the invention will be rendered by reference to a specific preferred embodiment(s) thereof which is/are illustrated in the appended drawings. Note particularly that the appended drawings are not necessarily drawn to scale. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention and its presently understood best mode for making and using the same will be described and explained with additional specificity and detail through the use of the accompanying drawings in which: 
     FIG. 1 is a perspective view of a clip shown mounting an electrical box to a closed side of a channel metal wall stud, embodying features of the present invention; 
     FIG. 2 is a perspective view of the clip of FIG. 1 shown mounting an electrical box to a wooden stud having a rectangular cross-section, embodying features of the present invention; 
     FIG. 3 is a top plan view of the clip of FIG. 1, shown mounting an electrical box, in cross-section, to a closed side of a channel-shaped metal wall stud, embodying features of the present invention; 
     FIG. 4 is a view of the clip of FIG. 1 in a flat configuration before bending, embodying features of the present invention; 
     FIG. 5 a front elevational view of the clip of FIG. 1, embodying features of the present invention; 
     FIG. 6 a right-side elevational view of the clip of FIG. 1, embodying features of the present invention; 
     FIG. 7 is a back elevational view of the clip of FIG. 1, embodying features of the present invention, and 
     FIG. 8 is a left-side elevational view of the clip of FIG. 1, embodying features of the present invention 
    
    
     DETAILED DESCRIPTION 
     Referring to the drawings, a representative one-piece sheet metal clip for mounting an electrical box B and other objects on metal S M  or wood S W  wall studs, embodying various features the present invention, is generally indicated throughout the figures by reference character  10 . Electrical box B is of a conventional type, and includes a generally rectangular peripheral side wall  11  having an open front end  12 , and a rear end that is closed by a rear wall  13 . The metal wall stud S M  illustrated in FIG. 1 is of generally channel shape having a web W surface at the closed side of the stud, and a pair of generally parallel opposing flange surfaces extending laterally outwardly and perpendicular from the web W surface. One flange F F  constitutes a front flange at the front of the stud and the other flange F R  constitutes a rear flange at the rear of the stud. Inwardly turned lip L surfaces are located at the outer edges of the flanges. The width of the flanges frequently varies from one manufacturer to another. In addition, the width of the lips L may also vary. While a metal stud is shown in FIG. 1, it will be understood that clip  10  of the present invention is also adapted for use with a conventional wood stud S W  of rectangular cross section, as illustrated in FIG. 2, which has a front face F F  at the front of the stud and a rear face F R  (not shown) at the rear of the stud. Also, for purposes of disclosure, the below discussion of clip  10 , when applicable, relates to both the metal stud S M  and the wood stud S W . 
     For economical manufacture, clip  10  is stamped from a flat sheet metal blank (FIG.  4 ), preferably heat-treated and spring-tempered steel, and is bent and integrally formed in accordance with a main bending profile so as to accommodate different wall stud sizes. As shown in FIG. 1, clip  10  is engageable with the front flange F F  surface of the stud S M  in a conventional manner for securing the clip  10  to the stud. Clip  10  includes a middle portion  14 , a first side portion  16  and a second side portion  17 . The first side portion  16  extends generally upwardly, as viewed in FIG. 3, from the left edge  18  of the middle portion  14 . At least one barb or prong  19 , preferably a first pair of barbs or prongs  19 , extend downwardly from the first side portion  16  and terminate at pointed tips  21 . The prongs  19  are bent so that they also project inwardly with respect to the middle portion  14 . Similarly, the second side portion  17  extends generally upwardly, as viewed in FIG. 3, from the right edge  22  of the middle portion  14 . At least one barb or prong  23 , preferably a second pair of barbs or prongs  23 , extend downwardly from the second side portion  17  and terminate at pointed tips  24 . The prongs  23  are bent so that they also project inwardly with respect to the middle portion  14 . 
     The lateral separation of the pointed tips  21 ,  24  of the first and second pair of prongs  19 ,  23  is sufficiently predetermined, typically less that the lateral width of the stud S M ,  50  that the pointed tips  21  of the first pair of prongs  19  are engageable with the lip L surface and the pointed tips  24  of the second pair of prongs  23  are engageable with the web W surface so that the prongs  19 ,  23  grip the stud S M  to secure the clip  10  onto the front flange F F  surface of the stud S M . Clip  10  may be further secured to the stud S M  by a fastener (not shown) such as a nail or screw received through a hole  26  in the middle portion  14  of the clip  10  and piercing the front flange F F  surface. 
     Extending generally upwardly from near the right edge  22  of the middle portion  14  on the second side portion  17 , as viewed in FIG. 3, is a pair of box clip arms, generally indicated at  27 . The box clip arms  27  include an angled portion  28  projecting slightly upwardly and laterally outwardly from the second side portion  17  of the clip  10 , and a clip portion  29  extending upwardly and slightly laterally inwardly from a lower edge  31  of the angled portion  28 . The box clip arms  27  and the second side portion  17  cooperate to form a channel means which is adapted to receive a front edge  32  of the side wall  11  of the electrical box B. At least one barb or prong  33 , preferably a third pair of barbs or prongs  33  having pointed tips, project inwardly and downwardly, as viewed in FIG. 3, from clip portions  29  of box clip arms  27 . The separation of these tips of the prongs  33  and the second side portion  17  of clip  10  is preferably less than the thickness of the side wall  11  of the electrical box B so that the tips of the prongs  33  resiliently engage the side wall  11  of the electrical box B when it is received in the channel means between the box clip arms  27  and the second side portion  17  for securing the box B in a fixed position. 
     At least one support member  34  projects generally laterally inwardly, as viewed in FIG. 3, from the distal end of the second side portion  17  preferably all the way to the web W surface of the stud S M . In a preferred embodiment, clip  10  utilizes a pair of support members  34 . Each support member  34  includes an inwardly or outwardly turned lip portion  36  for engaging the web W surface during operation. When the clip  10  is attached to the stud S M  and the electrical box B is clipped onto the clip  10 , as shown in FIGS. 1-3, the support members  34  extend between side wall  11  of the electrical box B and the webbing W surface of the stud S M  to provide support for the box B when a force is applied inward of the box B, in the direction of arrow A (FIG.  3 ), against flexing of the clip  10 . When an inward force is applied in the direction of arrow A, the second side portion  17  engages the side wall  11  of the electrical box B while the turned lip portions  36  of the support members  34  engage the webbing W surface. This provides support against and substantially prevents any or further laterally inward movement of the box B. 
     While the clip  10  is shown attached to the closed side of the stud S M  it should be understood that the length of the support members  34  may be adjusted to accommodate attachment of the clip  10  to the open side of the stud S M . Furthermore, support members  34  may be utilized and function substantially the same when clip  10  is attached to a wood stud S W . 
     Although a preferred embodiment(s) of the present invention has been described above by way of example, it will be understood by those skilled in the field that modifications may be made to the disclosed embodiment(s) which are within the scope of the invention as defined by the appended claims.