Abstract:
An electrical device mounting assembly for recessed mounting of high and low voltage components in order to provide electrical power and low voltage signals to a television or home entertainment center is provided. Mounting surfaces are provided within the mounting assembly to recess electrical components therein and behind the wall surface. The assembly includes a mounting frame for receipt of mounting devices such as high voltage boxes and low voltage mounting plates. The mounting devices are secured at an angle with respect to the mounting frame, thereby minimizing the depth of the mounting frame while providing sufficient space for recessing plug ends of electrical cords and terminal ends of signal cables within the wall. The electrical device mounting assembly provides a recessed area on a wall for mounting all the various electrical and signal hookups for a television or home entertainment system.

Description:
FIELD OF THE INVENTION 
     This invention relates to electrical box assemblies for mounting components for high and low voltage devices and specifically to an electrical device mounting assembly that can be easily installed on an interior wall of a building and provide high and low voltage components connections to a television, computer, or home stereo system. 
     BACKGROUND OF THE INVENTION 
     With the proliferation of high definition televisions and various auxiliary devices, such as digital videodisc players, game stations, and surround sound systems, there is a need to manage the connections between these devices to ensure there is adequate power and also to manage the myriad of cables and cords that accompany such systems. Additionally, many electrical boxes for both high and low voltage components mount the components flush with the wall, which makes the plugs or connectors that mate with the wall-mounted components protrude from the wall, thereby making it difficult to mount an electrical device such as a television close to the wall. Electrical plugs or cords that extend from the wall are also susceptible to damage, such as from vacuum cleaners or other household hazards which may brush against the plugs or cords. 
     What is needed therefore is an electrical device mounting assembly that provides connection points for both high and low voltage components, provides isolation of high voltage connections from low voltage connections, provides features for managing the plethora of cables and wiring associated with modern television systems, and recesses the end connector of cords or cables to protect the plug ends of cords or end connectors of cables from undesirable contact with household appliances or household occupants. Furthermore, for electrical mounting assemblies that recess the ends of electrical cords within the wall, it is desirable to minimize the depth of the mounting assemblies to minimize the size and cost of manufacturing such assemblies. 
     SUMMARY OF THE INVENTION 
     The invention is an electrical device mounting assembly that enables mounting of high and low voltage components in a single assembly for providing electrical supply and low voltage signals to a television or home entertainment center. The electrical device mounting assembly provides mounting locations for recessing various electrical components behind the wall surface to make them unobtrusive and out of the way. The mounting assembly includes a mounting frame for housing high voltage electrical boxes and low voltage mounting plates. The mounting frame enables mounting of the high voltage boxes and low voltage mounting plates at an angle with respect to the wall, thereby minimizing the depth of the mounting frame while providing sufficient space for recessing plug ends of electrical cords and terminal ends of signal cables within the wall. The low voltage mounting plates are capable of accepting standard jacks for broadband cable, direct TV, surround sound cabling, or phone systems. The electrical device mounting assembly enables easy consolidation of all the various electrical and signal hookups for TV or home entertainment systems. 
     OBJECTS AND ADVANTAGES 
     The electrical device mounting assembly of the present invention provides several advantages over the prior art, including:
         (1) Mounting surfaces are provided for mounting both high and low voltage components. An electrical box, integral with the box member of the assembly, is provided for housing and isolating high voltage components, such as a duplex receptacle to provide line voltage to a TV or other electrical device. Mounting surfaces are also provided for mounting several low voltage components, such as a coupling plate for a coaxial cable.   (2) Mounting surfaces are at an angle with respect to the front of the electrical device mounting assembly thereby advantageously minimizing the depth of the mounting assembly.   (3) The electrical device mounting assembly includes a mounting frame that extends within the wall, thereby recessing electrical components within the wall to render them unobtrusive and out of the way. Recessing the electrical components enables mounting the recipient electrical device, such as a television, substantially flush against the wall and also advantageously recesses the plug ends of cords or end connectors of cables within the wall surface.   (4) The electrical device mounting assembly provides features for managing the plethora of cables and wiring associated with modern television systems thereby providing a clean installation that is unobtrusive and minimizes the amount of wires and cables running between the wall and the television, speaker system, or other components of a home entertainment system.       

     These and other objects and advantages of the present invention will be better understood by reading the following description along with reference to the drawings. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exploded perspective view of a first embodiment of an electrical device mounting assembly according to the present invention. 
         FIG. 2  is a front view of a mounting frame that forms a portion of the electrical device mounting assembly of  FIG. 1 . 
         FIG. 3  is a side view of the mounting frame as viewed from the top side of  FIG. 2 . 
         FIG. 4  is a sectional view of the mounting frame taken along line  4 - 4  of  FIG. 2 . 
         FIG. 5  is a sectional view of the mounting frame taken along line  5 - 5  of  FIG. 2 . 
         FIG. 6  is a perspective view of a low voltage plate that forms a portion of the electrical device mounting assembly of  FIG. 1 . 
         FIG. 7  is a side view of the low voltage plate of  FIG. 6 . 
         FIG. 8  is an end view of the low voltage plate of  FIG. 6 . 
         FIG. 9  is a perspective view of a high voltage box that forms a portion of the electrical device mounting assembly of  FIG. 1 . 
         FIG. 10  is a side view of the high voltage box of  FIG. 9 . 
         FIG. 11  is an end view of the high voltage box as viewed from the bottom of  FIG. 9 . 
         FIG. 12  is an exploded perspective view of the electrical device mounting assembly of the present invention including a high voltage component mounted in the high voltage box and two low voltage components mounted in the low voltage plate. 
         FIG. 13  is a perspective view of the electrical device mounting assembly of the present invention mounted to a wall and with a high voltage component and two low voltage components mounted therein. 
         FIG. 14  is a perspective view of a second and preferred embodiment of an electrical device mounting assembly according to the present invention mounted to a wall. 
     
    
    
     TABLE OF NOMENCLATURE 
     The following is a listing of part numbers used in the drawings along with a brief description: 
     
       
         
               
               
             
               
               
             
           
               
                   
               
               
                 Part Number 
                 Description 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 20 
                 electrical device mounting assembly, first embodiment 
               
               
                 22 
                 mounting frame 
               
               
                 24 
                 low voltage mounting plate 
               
               
                 26 
                 high voltage box 
               
               
                 28 
                 trim plate 
               
               
                 30 
                 side wall 
               
               
                 32 
                 end wall 
               
               
                 34 
                 back wall 
               
               
                 35 
                 corner wall 
               
               
                 36 
                 aperture in back wall 
               
               
                 38 
                 open area 
               
               
                 40 
                 tab 
               
               
                 42 
                 cable opening 
               
               
                 44 
                 boss 
               
               
                 46 
                 front face of mounting frame 
               
               
                 48 
                 spacer 
               
               
                 50 
                 front face of spacer 
               
               
                 52 
                 slot 
               
               
                 54 
                 gap 
               
               
                 56 
                 enclosure of mounting frame 
               
               
                 58 
                 brace 
               
               
                 60 
                 second brace 
               
               
                 62 
                 raised area 
               
               
                 64 
                 first frame 
               
               
                 66 
                 second frame 
               
               
                 68 
                 corner wall of frame 
               
               
                 70 
                 first lip 
               
               
                 72 
                 mounting boss 
               
               
                 73 
                 mounting bore 
               
               
                 74 
                 second lip 
               
               
                 75 
                 frame opening 
               
               
                 76 
                 component connection point 
               
               
                 78 
                 component bore 
               
               
                 79 
                 component boss 
               
               
                 80 
                 back side of low voltage plate 
               
               
                 82 
                 filet 
               
               
                 84 
                 sidewall of electrical box 
               
               
                 86 
                 end wall of electrical box 
               
               
                 88 
                 electrical box enclosure 
               
               
                 90 
                 recessed area 
               
               
                 92 
                 knockout 
               
               
                 94 
                 stud 
               
               
                 96 
                 fastener 
               
               
                 98 
                 fastener 
               
               
                 99 
                 attachment arrangement 
               
               
                 100 
                 duplex receptacle 
               
               
                 102 
                 CATV connector plate 
               
               
                 104 
                 end flange 
               
               
                 106 
                 inner aperture 
               
               
                 108 
                 outer aperture 
               
               
                 110 
                 fastener 
               
               
                 112 
                 bore 
               
               
                 114 
                 opening in trim plate 
               
               
                 116 
                 mounting fastener 
               
               
                 120 
                 electrical device mounting assembly, second embodiment 
               
               
                 122 
                 trim plate 
               
               
                 124 
                 first end flange 
               
               
                 126 
                 second end flange 
               
               
                 130 
                 fastener 
               
               
                 132 
                 end of trim plate 
               
               
                 134 
                 electrical fitting or connector 
               
               
                 Θ1 
                 angle of first brace with respect to front face 
               
               
                 Θ2 
                 angle of second brace with respect to front face 
               
               
                 Θ3 
                 angle of first frame with respect to second frame 
               
               
                 Θ4 
                 angle of first lip with respect to first frame 
               
               
                 Θ5 
                 angle of second lip with respect to second frame 
               
               
                 D1 
                 depth of mounting frame 
               
               
                 D2 
                 spacing between apertures in trim plate 
               
               
                   
               
             
          
         
       
     
     DETAILED DESCRIPTION OF THE INVENTION 
     With reference to  FIG. 1  there is shown a first embodiment of an electrical device mounting assembly  20  according to the present invention. The electrical device mounting assembly  20  includes a mounting frame  22 , two mounting devices including a low voltage mounting plate  24  and a high voltage box  26 , and a trim plate  28 . 
     Referring to  FIGS. 2-5 , the mounting frame  22  has walls  30  and  32  including two side walls  30  and two end walls  32 , a back wall  34  extending over a portion of the rear of the mounting frame  22  at its center and two corner walls  35 . Several apertures  36  are provided in the back wall  34 . Two large open areas  38  are provided on either side of the partial back wall  34  and a plurality of tabs  40  are provided on the mounting frame  22  extending inward from the end walls  32 . The side walls  30  include cable openings  42  therein and the back wall  34  includes bosses  44  that are coincident with the apertures  36  in the back wall. The side walls  30  and end walls  32  of the mounting frame  22  terminate in a planar front face  46 . Integral spacers  48  extend outwards from the end walls  32  and each include a flat front face  50  that is planar with the front face  46  of the mounting frame  22 . The integral spacers  48  are preferably ½-inch in length and thereby enable an installer to rapidly and accurately orient the mounting frame  22  with respect to a stud (not shown) in a new work situation in order to properly allow the proper spacing for applying conventional ½-inch drywall over the stud. A plurality of slots  52  are provided in the side walls  30  and end walls  32  of the mounting frame  22 . The tabs  40  are offset from the corner walls  35  thereby creating a gap  54  there between. As shown in  FIG. 4 , the mounting frame  22  includes an enclosure  56  defined by the side walls  30  and end walls  32  and a plurality of braces  58  and second braces  60  extending from each of the side walls  30  into the enclosure  56 . Each brace  58  is at an angle of Θ 1  with respect to the front face  46  and each second brace  60  is at an angle of Θ 2  with respect to the front face  46 . As will be described herein, it is critical to the present invention that the braces  58  and second braces  60  are each at an angle with respect to the front face  46  of the mounting frame  22  as this will insure that multiple component housings (not shown) can be mounted within the mounting frame  22  while minimizing the depth of the mounting frame  22  with the depth of the mounting frame  22  being defined as the distance between the front face  46  and the back wall  34  and shown as distance D 1  in  FIG. 5 . Most preferably, the depth D 1  of the mounting frame  22  according to the present invention is 3.8-inches or less, which depth is kept to a minimum by orienting the mounting devices  24  and  26  at an angle with respect to the front face  46  of the mounting frame  22 . Thus, the mounting of the mounting devices  24  and  26  at the desired angle achieves the unexpected results of enabling the fitting of a substantial number of mounting devices  24  and  26  in a mounting assembly  20  that extends a relatively short distance into the wall while still providing space for recessing the installed electrical components and any connected electrical cord plugs. As shown in  FIG. 4 , the braces  58  and  60  are formed by substantially triangular-shaped raised areas  62  in the side walls  30  of the mounting frame  22 . The raised areas  62  extend from both the top and bottom side walls  30  and provide the bracing surfaces  58  and  60  thereon. 
     With reference to  FIGS. 6-8  there is shown a low voltage mounting plate  24  that may form a portion of an electrical device mounting assembly according to the present invention. The low voltage mounting plate  24  includes a first frame  64  and a second frame  66  integral with one another at a corner wall  68 . The frames  64  and  66  are at an angle Θ 3  with respect to one another, which angle is preferably between 60 and 120 degrees and more preferably is 90 degrees, as depicted in  FIG. 8 . A first lip  70  extends at an angle Θ 4  from the first frame  64  and two mounting bosses  72  having mounting bores  73  therein extend from the first lip  70 . The second frame  66  also includes a second lip  74  extending there from with the second lip  74  extending at an angle Θ 5  from the second frame  66 . When the angle Θ 3  of the first frame  64  with respect to the second frame  66  is 90 degrees, the angle Θ 4  of the first lip  70  with respect to the first frame  64  is preferably 60 degrees and the angle Θ 5  of the second lip  74  with respect to the second frame  66  is preferably 30 degrees. The frames include frame openings  75  therein. Component connection points  76  extend into the frame openings  75  and include component bores  78  therein. The component connection points  76  include component bosses  79  extending from the back side  80  of the low voltage mounting plate  24 . A filet  82  is provided on the back side  80  of the low voltage mounting plate  24  extending between the frames  64  and  66 . When the low voltage mounting plate  24  is molded of plastic, the filet  82  is molded integrally with the low voltage mounting plate  24  and adds strength to the plate  24  at the point where the two frames  64  and  66  meet. 
     Referring to  FIGS. 9-11 , the high voltage box  26  includes many elements in common with the low voltage frame including a first frame  64 , second frame  66 , first lip  70 , second lip  74 , mounting bosses  72 , and component connection points  76 . The high voltage box  26  also includes a sidewall  84  and end walls  86  that cooperate with the second frame  66  to provide an electrical box enclosure  88  for accepting a high voltage electrical component (not shown) therein. A recessed area  90  is provided in each end wall  86  with a knockout  92  provided in each recessed area. 
     Reference is made to  FIG. 12  for an explanation of the operation of the electrical device mounting assembly  20  of the present invention. The electrical device mounting assembly  20  can be mounted to a wall and configured to hold two high voltage electrical boxes  26 , two low voltage mounting plates  24 , or one high voltage electrical box and one low voltage mounting plate. Thus, the electrical device mounting assembly can be configured to provide the proper amount of high and low voltage connection points depending on the needs of the situation. The particular arrangement depicted in  FIG. 12  depicts the electrical device mounting assembly  20  being configured to hold one high voltage electrical box  26  and one low voltage mounting plate  24 . The electrical device mounting assembly can be used for either new work, where sheetrock has not been installed over the studs, or old work situations. For an old work installation, a portion of the existing sheetrock is removed, typically between two studs, in the location where electrical services are required. One end of the electrical device mounting assembly  20  is typically secured to a stud  94  with fasteners  96  as shown. 
     After the electrical device mounting assembly  20  is secured at one end to the stud  94 , the assembly may be configured with two low voltage plates, two high voltage boxes, or one of each as desired. The high voltage box  26  and low voltage plate  24  can be installed into the electrical device mounting assembly  20  in any order by sliding the second lip  74  of the second frame  66  into the gaps  54  between the tabs  40  and corner wall  68 . The tabs  40  perform a critical function for the electrical device mounting assembly  20  as they enable an installer to rapidly configure the box with mounting devices  24  and  26 . The tabs  40  enable the mounting device  24  or  26  to easily seat in its proper place in the box assembly  20  as the tabs  40  enable the second lip  74  of the mounting device to slide into the gaps  54  formed by the tabs. Brace  58  and second brace  60  of mounting frame  22  brace and support the first frame  64  and second frame  66  respectively of the low voltage mounting plate  24  and high voltage box  26  when they are inserted into the mounting frame  22  and position the frames  64  and  66  at the desired angle with respect to the front face  46  of the mounting frame  22 . The mounting devices  24  and  26  are then secured to the mounting frame  22  by driving fasteners  98  through bosses  72  of mounting devices  24  and  26  into apertures  36  in the back wall  34  of mounting frame  22 . Fasteners  98  and bosses  72  therefore form an attachment arrangement  99  for securing the mounting devices  24  and  26  within the enclosure  56  of the mounting frame  22 . In  FIG. 12 , the high voltage box  26  is depicted with a duplex receptacle  100  installed therein and low voltage mounting plate  24  is depicted with two CATV connector plates  102  installed therein. The installation is completed by securing trim plate to the mounting frame  22 . Trim plate  28  includes two end flanges  104  with inner apertures  106  and outer apertures  108  therein. After the mounting frame  22  has been configured, fasteners  110  are driven into bores  112  in each corner of the front face  46  of the mounting frame  22 . The high and low voltage electrical components  100  and  102  will then be accessible through the opening  114  in trim plate  28 . After the trim plate  28  is secured to the mounting frame  22 , mounting fasteners  116  may be driven through the end flange  104  opposite the stud  94  to secure the opposing end of the electrical device mounting assembly  20  to the wall. 
     The completed electrical device mounting assembly  20  is depicted in  FIG. 13 . A low voltage mounting plate  24  has been installed in the right side of the assembly and a high voltage box  26  has been installed in the left side of the assembly. If an alternative arrangement of high and low voltage components is desired, the electrical device mounting assembly  20  may be configured with two high voltage boxes or with two low voltage mounting plates in lieu of one of each type electrical mounting device. 
     With reference to  FIG. 14  there is shown a second and preferred embodiment of an electrical device mounting assembly  120 . Mounting assembly  120  includes a mounting frame  22 , low voltage mounting plate  24 , and high voltage box  26  similar to the first embodiment. Mounting assembly  120  however includes a trim plate  122  in which the end flanges are nonsymmetrical including a first end flange  124  and a second end flange  126 . As shown in  FIG. 14 , the second end flange  126  is wider than the first end flange  124 . Trim plate  122  is sized to provide spacing equal to the standard spacing between studs. The spacing, denoted by D 2  in  FIG. 14 , is preferably 16-inches between the outer apertures  108  in the end flanges  124  and  126  to match the conventional center-to-center spacing between adjacent studs. The distance between sidewall  30  of mounting frame  22  and the outer aperture  108  of first end flange  124  is approximately half the width of a conventional stud  94 . Thus the mounting frame  22  can be jammed against a stud  94  and secured thereto with fasteners  130  driven through slots  52  in sidewall  30  into stud  94 . After the low voltage mounting plate  24  and high voltage box  26  are installed in the mounting frame  22 , trim plate  122  is secured to the mounting frame  22  by fasteners  110 . The opposite end  132  of the trim plate  122  is then secured to the opposite stud  94  with fasteners  116 . The second embodiment of the trim plate  122  according to the present invention therefore provides the ability to anchor the electrical device mounting assembly  120  to a stud  94  at both ends of the assembly, thereby providing an electrical device mounting assembly  120  that is secured at both ends to the wall. 
     As shown in  FIG. 11 , the high voltage box  26  may include a knockout or removable wall portion  92  therein in the recessed area  90  in one of the end walls  86 . The recessed area  90  in the sidewall  86  enables the use of electrical fittings or connectors such as the Black Button™ push-in fitting or connector  134  for connecting non-metallic cable to electrical boxes, which connector  134  is available from Arlington Industries of Scranton, Pa. The recessed area  90  permits use of the connectors  134  while preventing the connectors from projecting beyond the sidewall  86  and interfering with placement of the electrical device mounting assembly  20  in locations where space is tightly restricted. 
     The various portions of the electrical device mounting assembly  20 , including the mounting frame  22 , low voltage mounting plate  24 , high voltage box  26 , and trim plate  28 , may be constructed of metal or plastic. Most preferably, the mounting frame  22 , low voltage mounting plate  24 , high voltage box  26 , and trim plate  28  are each molded in one piece of plastic. Suitable plastics include polycarbonate and polyvinylchloride. 
     Having thus described the invention with reference to a preferred embodiment, it is to be understood that the invention is not so limited by the description herein but is defined as follows by the appended claims.