Abstract:
An electrical box with a mounting system is disclosed. The electrical box includes a main body having a back panel with a raised portion and a protuberance formed on an outer surface of the back panel. The mounting tab is configured for mounting the main body to a mounting structure. An electrical box assembly including the mounting tab having a first aperture that receives the protuberance of the main body, and a method for mounting the electrical box on a mounting structure, are also disclosed.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority to U.S. Provisional Patent Application Ser. No. 60/861,639, filed Nov. 28, 2006, the entire disclosure of which is incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to an electrical box and more particularly to an electrical box having a mounting system for mounting the box to one of a plurality of different mounting structures. 
       BACKGROUND OF THE INVENTION 
       [0003]    Typically, an electrical box is used to support and contain electrical devices and wiring in a convenient manner. The electrical box protects the wiring and the electrical devices contained therein. A cover plate or door can be provided to further protect the wiring and the electrical devices, and militate against accidental electrocution of a user. In some instances, the box is connected to a joist or other structural component of a building. In other instances, the box is connected to other structures such as a pole, for example. 
         [0004]    Prior art electrical boxes include mounting systems that facilitate a connection to certain mounting structures, but not to other mounting structures. Accordingly, an electrical box having a correct mounting system must be selected for each application of the electrical box. Selection of the correct electrical box can be time consuming. Further, if an incorrect electrical box is selected and used, the connection between the electrical box and the mounting structure facilitated by the mounting system may be inadequate, which is undesirable. 
         [0005]    It would be desirable to produce an electrical box which can be readily and securely mounted to a plurality of different mounting structures, wherein a complexity and cost of the box are minimized, and a functionality of the box is maximized. 
       SUMMARY OF THE INVENTION 
       [0006]    True to the present invention, an electrical box which can be readily and securely mounted to a plurality of different mounting structures, wherein a complexity and cost of the electrical box are minimized, and a functionality of the electrical box is maximized, has surprisingly been discovered. 
         [0007]    In one embodiment, an electrical box includes a main body having a back panel with a raised portion. The back panel has an outwardly extending protuberance formed on an outer surface thereof. The main body is adapted to be joined with a mounting tab for mounting the main body to a mounting structure. 
         [0008]    In a further embodiment, an electrical box assembly has a main body with a back panel with a raised portion. The back panel has an outwardly extending protuberance formed on an outer surface thereof. The electrical box assembly includes a mounting tab having a first aperture formed therein. The first aperture receives the protuberance of the main body. A first fastener is disposed in the first aperture through an opening formed in the protuberance and attaches the mounting tab to the main body. 
         [0009]    In an additional embodiment, a method for mounting an electrical box is described. The method first includes the steps of providing a main body including a back panel with a protuberance formed thereon, wherein the protuberance has an opening formed therein adapted to receive a first fastener. Additionally, a mounting tab is provided, having a first aperture and a second aperture. The protuberance of the back panel is disposed within the first aperture of the mounting tab. A first fastener is inserted through the first aperture and into the opening of the protuberance to fasten the mounting tab to the main body. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment when considered in the light of the accompanying drawings in which: 
           [0011]      FIG. 1  is a front perspective view of an electrical box according to an embodiment of the invention; 
           [0012]      FIG. 2  is a rear perspective view of the electrical box illustrated in  FIG. 1 ; 
           [0013]      FIG. 3  is a perspective view of an elongated mounting tab for mounting the electrical box illustrated in  FIGS. 1 and 2 ; 
           [0014]      FIG. 4  is a perspective view of the electrical box illustrated in  FIGS. 1 and 2  joined with the elongated mounting tab illustrated in  FIG. 3 ; 
           [0015]      FIG. 5  is a rear perspective view of the electrical box illustrated in  FIG. 1  joined with the elongated mounting tab; 
           [0016]      FIG. 6  is a perspective view of a mounting tab for mounting the electrical box illustrated in  FIGS. 1 and 2 ; and 
           [0017]      FIG. 7  is a perspective view of the electrical box illustrated in  FIGS. 1 and 2  joined with a plurality of the mounting tabs illustrated in  FIG. 6 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0018]    The following detailed description and appended drawings describe and illustrate various exemplary embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner. In respect of the methods disclosed, the steps presented are exemplary in nature, and thus, are not necessary or critical. 
         [0019]      FIG. 1  illustrates an electrical box  10  according to an embodiment of the invention. The electrical box  10  includes a main body  12  having a substantially rectangular cross-sectional shape. It is understood that the electrical box  10  may have other cross sectional shapes as desired. The main body  12  includes a top panel  14 , a bottom panel  16 , a first side panel  18 , a second side panel  20 , a front panel  22 , and a back panel  24 . 
         [0020]    The front panel  22  is hingedly attached to the first side panel  18 . The front panel  22  facilitates a selective opening and closing of the electrical box  10 . It is understood that the front panel  22  can be pivotally attached to other portions of the electrical box  10  as desired. In the embodiment shown, the front panel  22  is removable from the main body  12 . Alternatively, the front panel  22  can be fixed to the main body  12 . The front panel  22  may be formed from a substantially transparent material. The front panel  22  can also be formed from other materials as desired. 
         [0021]    Optionally, the electrical box  10  may include a locking device  23  attached thereto. The locking device  23  shown in  FIG. 1  includes a locking tab  25  disposed on the front panel  22  and a tab receiving and securing device  27  disposed on the second side panel  20 . It is understood that the locking device  23  and the securing device  27  can be disposed on other structure of the electrical box  10  as desired. It is also understood that other types of locking devices can be used. 
         [0022]    As shown in  FIG. 2 , the back panel  24  includes a first surface  26  having a plurality of outwardly extending protuberances  28  formed thereon. It is understood that additional or fewer protuberances  28  can be formed on the first surface  26  as desired. The protuberances  28  can include apertures  30  formed therein. The apertures  30  are adapted to receive a first fastener  51 . The apertures  30  may be adapted to receive a threaded metal insert, for example, that enables a repeated insertion and removal of the first fastener  51 . 
         [0023]    The back panel  24  also includes a second surface  32  spaced apart from the first surface  26 . The second surface  32  is disposed between the protuberances  28  formed adjacent to the top panel  14  and the protuberances  28  formed adjacent to the bottom panel  16 . In the embodiment shown, the second surface  32  extends across an entire width W of the main body  12 . It is understood that the second surface  32  can extend across a larger or smaller distance as desired. Gaps G are formed on the first surface  26  between the protuberances  28  and the second surface  32 . 
         [0024]    An inner surface of the back panel  24  includes a plurality of protuberances  34  formed thereon. The protuberances  34  include apertures  36  formed therein. Optionally, additional structure (not shown) such as a mounting panel can be mounted in the electrical box  10  and fastened to the protuberances  34 . 
         [0025]      FIG. 3  shows an elongated mounting tab  40  adapted to be fastened to the electrical box  10 . The mounting tab  40  includes a plurality of first apertures  44  and a plurality of second apertures  42 . The first apertures  44  have lips  45  formed at an end of the first apertures  44 . The lip  45  of each first aperture  44  defines a central opening adopted to receive the first fastener  51 . The protuberances  28  are disposed in the first apertures  44  and abut the lips  45 . The first fasteners  51  are inserted into the openings defined by the lips  45  to fasten the protuberances  28  to the mounting tab  40 . The second apertures  42  are adapted to receive the second fasteners  53 . A spacing between the second apertures  42  substantially corresponds to a spacing of apertures formed in a structure (not shown) to which the electrical box  10  will be mounted. It is understood that additional apertures (not shown) can be formed in other locations on the mounting tab  40  as desired. 
         [0026]    When fastened to the electrical box  10  as shown in  FIG. 4 , the plurality of first apertures  44  of the mounting tab  40  are aligned with the protuberances  28  formed on the first surface  26  of the back panel  24 . The protuberances  28  are disposed in the first apertures  44  and abut the lips  45 . The first fasteners  51  are inserted into the openings defined by the lips  45  to fasten the protuberances  28  to the mounting tab  40 . Accordingly, movement between the mounting tab  40  and the electrical box  10  is militated against. If the first fasteners  51  have a length that is less than a length of the protuberances  28  formed on the back panel  24 , the ends of the first fasteners  51  remain in the protuberances  28  when fastened to the electrical box  10 . Accordingly, the first fasteners  51  do not protrude into the main body  12  of the electrical box  10 , where the first fasteners  51  could interfere with or damage wiring (not shown) or other electrical devices (not shown) inside of the main body  12  of the electrical box  10 . As defined herein, wiring includes electrical wires, cables, and the like, for example. 
         [0027]    Once the mounting tab  40  is fastened to the electrical box  10 , the assembled electrical box  10  is positioned as desired, such as adjacent a single mounting surface (not shown) or a pair of substantially parallel mounting surfaces (not shown), for example. It is understood that the electrical box  10  can be positioned in other locations as desired. 
         [0028]      FIG. 5  shows the second fasteners  53 , which are inserted through the plurality of second apertures  42  formed in the mounting tab  40  and attached to the mounting surface to secure the electrical box thereto. 
         [0029]      FIG. 6  shows a mounting tab  50  adapted to be fastened to the electrical box  10  in accordance with another embodiment of the invention. The mounting tab  50  includes a first aperture  54  that is aligned with one of the protuberances  28  formed on the first surface  26  of the back panel  24 . The first aperture  54  has a lip  55  formed at an end of the first aperture  54 . One of the protuberances  28  are disposed into the first aperture  54  and abuts the lip  55 . A first fastener  51  is inserted into the opening defined by the lip  55  to fasten one of the protuberances  28  to the mounting tab  50 . The mounting tab  50  has a second aperture  52  formed therein adapted to receive the second fastener  53 . 
         [0030]      FIG. 7  shows a particular embodiment where the mounting tab  50  is secured by a first fastener  51 , the mounting tab is permitted to rotate about one of the protuberances  28 . The raised portion  32  of the back panel  24  and an outer surface of each mounting tabs  50  lie on substantially the same plane. Thus, rotation of the mounting tab  50  to a position behind the raised portion  32  is militated against. The raised portion  32  may have a substantially planar surface. The substantially planar surface of the raised portion  32  may be adapted to fit tightly against and abut the mounting surface. Thus, the raised portion  32  may support the back panel  24 . The raised portion  32 , not being spaced apart from the mounting surface, may also provide an aesthetically pleasing appearance. 
         [0031]    The raised portion  32  may be formed, for example, by stamping or molding the raised portion  32  in the back panel  24 . Accordingly, it should be appreciated that the raised portion  32  may form a corresponding recess in the inner surface of the back panel  24 . The recess facilitates a greater interior volume of the electrical box  10 . When the mounting panel is disposed on the protuberances  34  on the interior surface, the recess may accommodate at least one of fasteners and wires that may be disposed between the mounting panel and the back panel  24 . 
         [0032]    A skilled artisan should understand that, if the first fastener  51  has a length that is less than a length of one of the protuberances  28  formed on the back panel  24 , the end of the first fastener  51  remains inside one of the protuberances  28  when fastened to the electrical box  10 . Accordingly, the first fastener  51  does not protrude into the main body  12  of the electrical box  10 , where the first fastener  51  could interfere with or damage wiring (not shown) or other electrical devices (not shown) inside of the main body  12  of the electrical box  10 . 
         [0033]    Once the mounting tab  50  is fastened to the electrical box  10 , the assembled electrical box  10  is positioned as desired, such as adjacent to a single mounting surface (not shown) or a pair of substantially parallel mounting surfaces (not shown), for example. It is understood that the electrical box  10  can be positioned in other locations as desired. The second fastener  53  is then inserted through the second aperture  52  formed in the mounting tab  50  and into the mounting structure to secure the electrical box  10  thereto. 
         [0034]    The electrical box  10  described above can be mounted using either the mounting tab  40  or the mounting tab  50 . If it is desired to adjust the location of the electrical box  10 , the second fastener  53  can be removed from the mounting structure which the electrical box  10  is mounted upon. If the other of the mounting tab  40  or the mounting tab  50  is needed for remounting the electrical box  10 , the first fasteners  51  can be removed from the protuberances  28 . Thereafter, whichever of the mounting tab  40  or the mounting tab  50  is needed to mount the electrical box  10  to the mounting structure is secured to the electrical box  10 . The electrical box  10  is then mounted to a new structure as described above. 
         [0035]    The electrical box  10  described above can be mounted to a plurality of different mounting structures by changing either the mounting tab  40  or the mounting tab  50  attached to the electrical box  10 . Accordingly, the same electrical box  10  can be used for different applications, rather than requiring a different box for different applications. 
         [0036]    While certain representative embodiments and details have been shown for purposes of illustrating the invention, it will be apparent to those skilled in the art that various changes may be made without departing from the scope of the disclosure, which is further described in the following appended claims.