Patent Publication Number: US-7902457-B2

Title: Adjustable mounting bracket

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a divisional application of Ser. No. 11/359,768, filed Feb. 23, 2006. 
    
    
     FIELD OF THE INVENTION 
     The present invention is directed to a mounting bracket for an electrical box or other electrical component. The invention is particularly directed to an adjustable mounting bracket for accommodating wall cavities of different depths between opposing walls. 
     BACKGROUND OF THE INVENTION 
     Electrical boxes are commonly mounted on various mounting brackets for securing the electrical box to a wall stud or other support. The electrical boxes are dimensioned to support electrical receptacles, switches and other components and must be securely mounted to the wall stud. Many electrical boxes include a mounting bracket extending from one side of the electrical box so that only one side of the electrical box is supported by the bracket. The opposite side of the electrical box often does not include a support so that some movement of the electrical box can occur during use. 
     To provide support of opposite ends of the electrical box, a number of brackets have been proposed. Typically, the bracket includes a first member for attaching to a wall stud and a second member connected to the opposite side of the box so that both sides of the electrical box are supported to resist movement with respect to the wall. 
     One example of a prior support bracket is disclosed in U.S. Pat. No. 4,399,922 to Horsley. The bracket as disclosed includes an extension arm bent at a right angle to a plate that supports the electrical box. The plate has one side edge provided with holes for securing the plate to a wall stud. The extension arm is formed on the opposite end and has a length to contact a wall on the other side of the wall stud. The extension member includes a series of score lines that can be broken off for use with walls having different depths. 
     Another device is disclosed in U.S. Pat. No. 4,732,356 to Medlin. This device also includes a plate member for supporting an electrical box. The plate includes a first end portion for attaching to the wall stud and a second end portion having an L-shaped arm to contact the opposite wall. A separate extension plate is attached to the L-shaped arm to adjust the length of the arm for different depths between the walls. 
     U.S. Pat. No. 4,688,693 to Medlin discloses an outlet box stabilizer bracket having an extension formed at a right angle to the bracket to contact an opposing wall. The extension is cut from the bracket and bent from the bracket to form a central opening in the bracket. 
     U.S. Pat. No. 4,964,525 to Coffey et al. discloses an electrical box mounting bracket for connecting to a wall stud. The bracket includes a pair of side mounted support legs that are bent at a right angle from the bracket to engage the opposite wall. 
     Examples of other mounting brackets that contact the opposing wall are disclosed in U.S. Pat. No. 4,645,089 to Horsley, U.S. Pat. No. 4,533,060 to Medlin, U.S. Pat. No. 4,569,458 to Horsley, U.S. Pat. No. 4,572,391 to Medlin, and U.S. Pat. No. 4,603,789 to Medlin. 
     While the devices and brackets have been generally suitable for the intended purpose of supporting an electrical box, there is a continuing need in the industry for improved support brackets and methods of producing the brackets. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a mounting bracket for supporting an electrical box or other electrical component. In particular, the invention is directed to a mounting bracket for mounting an electrical component to a wall stud or other support. 
     A primary feature of the invention is to provide a mounting bracket for an electrical box or electrical component formed as a unitary one piece member. In one embodiment, the mounting bracket is formed from a sheet material such as steel that can be folded to a shape to support the electrical box or electrical component. 
     Another feature of the invention is to provide an electrical outlet box bracket that is attached to a wall stud and is able to support an electrical box by contacting an opposing wall. 
     A further feature of the invention is to provide a bracket for supporting an electrical box where the bracket has a support plate to contact an opposing wall and where the support plate can accommodate wall cavities of different depths. One end of the bracket can be attached to a wall stud or other support member while the support plate supports the opposite end to resist bending of the bracket. 
     Still another feature of the invention is to provide a bracket for supporting an electrical box where the bracket includes a support plate and an integrally formed extension plate. The extension plate can be folded in a generally outward direction with respect to the support plate to contact an opposing wall to support the electrical box. 
     A further feature of the invention is to provide a bracket for supporting an electrical box and mounting the electrical box to a wall stud. The bracket has a support plate extending at a right angle to the bracket and has a length to contact an opposing wall to support the bracket and resist movement of the bracket and the electrical box with respect to the wall stud. An extension plate is integrally formed with the support plate and can be folded outwardly to an extended position for contacting an opposing wall in a deep wall cavity so that the bracket can accommodate wall cavities of different depths. The extension plate can be cut from the support plate and folded outwardly to form a central opening with the support plate. In another embodiment, the extension plate is at least one and preferably two legs cut from the support plate which can be folded outwardly. In preferred embodiments, the extension plate has a bendable locking tab that can be folded over a portion of the support plate to lock the extension plate in the extended position. 
     These and other features of the invention are basically attained by providing an adjustable outlet box mounting bracket formed from a unitary piece of stiff sheet material. The bracket comprises a front mounting panel having a central opening with a dimension to accommodate an electrical outlet box. A plurality of first openings receive screw heads for coupling the front mounting plate to the electrical outlet box. A plurality of second openings receive fasteners for mounting the front mounting panel to a wall stud. A stabilizing plate extends from the front mounting panel at a right angle and has a first end connected to the front mounting panel and a second end to engage an opposing wall surface spaced from a front wall a first distance during use. An extension plate is coupled to the stabilizing plate at the second end and is bendable from a first position to a second extended position extending away from the stabilizing plate. The extension plate has a first end, a second end and an outer end for engaging an opposing wall surface spaced from the front wall a second distance. 
     The various aspects of the invention are further attained by providing an electrical box mounting bracket which comprises a front mounting panel having a central opening with a dimension to accommodate an electrical box. A plurality of first openings receive screw heads for attaching the electrical box to the front mounting panel. A plurality of second openings receive fasteners for mounting the front mounting panel to a wall stud. A stabilizing plate has a first end coupled to and extending from the front mounting panel and having a second end to engage a first opposing wall surface spaced from a front wall a first distance during use. An extension plate is coupled to the stabilizing plate about a first fold line and is bendable from a first position to an extended second position to engage a second opposing wall surface spaced from the front wall a second distance. A bendable locking tab is integrally formed with the bracket to secure the extension plate in the extended position. 
     The features of the invention are also attained by providing an electrical box mounting bracket which comprises a front mounting panel having a central opening with a dimension to accommodate an electrical box. A plurality of first openings receives screw heads for coupling the electrical box to the front mounting plate and a plurality of second openings for fasteners for mounting the front mounting panel to the wall stud. A stabilizing plate is coupled to a side of the front mounting panel and is bendable about a fold line to an extended position wherein an outer end of the stabilizing plate engages an opposing wall surface spaced from a front wall a first distance during use. An extension plate is integrally formed with the stabilizing plate and has a first end portion and a second end portion coupled to the outer end of the stabilizing plate by a fold line and a second end portion spaced from the first end portion. The extension plate is bendable about the fold line between a first retracted position and a second extended position where the second end portion extends away from the front mounting plate. 
     These and other aspects and features of the invention will become apparent from the following detailed description of the invention which taken in conjunction with the annexed drawings will become apparent to one skilled in the art. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following is a brief description of the drawings, in which: 
         FIG. 1  is a perspective view of the mounting bracket in a first embodiment of the invention showing the stabilizing plate and extension plate; 
         FIG. 2  is a top end view of the stabilizing plate of  FIG. 1  with the extension plate in a first position and showing the wall structure; 
         FIG. 3  is a perspective view of the mounting bracket of  FIG. 1  showing the extension plate in a second extended position; 
         FIG. 4  is a cross-sectional view of the mounting bracket of  FIG. 1  taken along line  4 - 4  of  FIG. 3  showing the locking tab coupled to the support plate; 
         FIG. 5  is an end view of the mounting bracket of  FIG. 1  showing the extension plate in the extended position contacting a wall; 
         FIG. 6  is an end view of the mounting bracket of  FIG. 1  showing the extension plate in a shortened form to contact a wall; 
         FIG. 7  is a top plan view of a cut blank for forming a mounting bracket in a second embodiment of the invention; 
         FIG. 8  is an end view of the bracket of  FIG. 7 ; 
         FIG. 9  is a perspective view of the folded bracket of  FIG. 7 ; 
         FIG. 10  is an end view of the folded bracket of  FIG. 7  showing the stabilizing plate contacting an opposing wall; 
         FIG. 11  is a perspective view of the mounting bracket of  FIG. 7  showing the extension plate in the extended position; 
         FIG. 12  is a partial cross-sectional view of the locking tab folded over the stabilizing plate; and 
         FIG. 13  is an end view of the mounting bracket attached to a wall stud and showing the extension plate in the extended position. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention is directed to a mounting bracket for an electrical box or other electrical device. In particular, the invention is directed to a mounting bracket for securing an electrical box to a wall stud and supporting the electrical box in a secure manner. 
     Referring to the drawings, a first embodiment of the invention is shown in  FIGS. 1-6 . As shown in  FIG. 1 , the mounting bracket  10  includes a front mounting plate  12 , a support plate  14  and an extension plate  16 . 
     Mounting bracket  10  in a preferred embodiment of the invention is formed from a single piece of sheet material having sufficient strength to support an electrical box during use. Typically, mounting bracket  10  is formed from a steel sheet that is cut, stamped or pierced to form a one piece unitary unit. As shown in  FIG. 1 , front mounting plate  12  has a substantially flat front face  18  and a side portion  20  offset from the front face  18  by a stepped portion  22 . Side portion  20  in the embodiment shown has a substantially rectangular shape with a plurality of apertures  24  for receiving fasteners for securing mounting bracket  10  to a wall stud  26  or other support shown in  FIG. 1 . Front mounting plate  12  has a central opening  28  having a dimension to receive an electrical box or other electrical component. Central opening  28  defines first and second side sections  30  and  32 . Top section  34  and bottom section  36  extend between side sections  30  and  32  to define the opening  28 . Front face  18  includes a plurality of apertures  38  for receiving screws or other fasteners for attaching an electrical box  40  to front plate  12  as shown in  FIG. 2 . 
     Support plate  14  in the embodiment of  FIGS. 1-8  extends substantially perpendicular to front plate  12  in a direction away from front face  18 . Support plate  14  has a first inner section  42  connected to side section  32  of front plate  12 . Support plate  14  has a second end section  44  forming an outer end  46  spaced from front plate  12 . 
     Extension plate  16  is integrally formed with support plate  14  and is cut or stamped from support plate  14  as shown in  FIG. 1 . A plurality of elongated apertures  48  are pierced in support plate  14  to define a fold line  50  between support plate  14  and extension plate  16 . Extension plate  16  has side edges  52  and an outer edge  54  as shown in  FIG. 3 . A plurality of spaced apart score lines that define fold lines  56  are formed in extension plate  16  that are substantially parallel to fold line  50 . Fold lines  56  are typically formed by stamping so that portions of extension plate  16  can be folded to reduce the effective length of extension plate  16 . A central opening  58  is formed in extension plate  16  by cutting or stamping. In the embodiment illustrated, a locking tab  60  is cut from central opening  58  into extension plate  16  in a direction toward fold line  50  as shown in  FIG. 1 . Locking tab  60  includes side edges  62  and an outer edge  64 . Extension plate  16  is cut to form top and bottom sections  66  and  68 , respectively, in support plate  14  that extend in a direction substantially perpendicular to front plate  12 . An embossed strengthening rib  70  is formed in each top and bottom section  66  and  68  to strengthen support plate  14  and resist bending or buckling. 
     In use, electrical box  40  is coupled to front plate  12  and side portion  20  is attached to wall stud  26 . Wall stud  26  supports a front wall  27  in phantom lines that overlies mounting bracket  10  in a conventional manner. An opposing rear wall  72  is attached to wall stud  26  on a side opposite mounting bracket  10 . Referring to FIG.  2 , wall stud  26  has a dimension indicated by arrow  74 . Support plate  14  has a length extending from front plate  12  corresponding substantially to the dimension of wall stud  26  so that the end  46  of support plate  14  contacts wall  72  to stabilize one end of the front plate  12 . Mounting bracket  10  is cantilevered from wall stud  26  by side portion  20 . To prevent front plate  12  from flexing or bending in a direction toward wall  72 , support plate  14  has a dimension to contact wall  72  and support mounting bracket  10 . 
     Mounting bracket  10  is able to accommodate wall structures having different depths by selectively adjusting the effective length of support plate  14 . For example, opposing wall  72  can be spaced a distance greater than the distance  74  shown in  FIG. 2 . Referring to  FIG. 5 , a wall stud  26  indicated by arrow  76  where opposing wall  72  is spaced from a front wall a distance greater than the length of support plate  14 . In this embodiment, extension plate  16  is folded outwardly from support plate  14  along fold line  50  from a first position shown in  FIG. 1  to a second position shown in  FIG. 3  where extension plate  16  extends away from support plate  14 . In the illustrated embodiment, extension plate  16  is folded flat against support plate  14  to be parallel thereto. As shown in  FIG. 3 , outer edge  54  of extension plate  16  is spaced from front plate  12  a distance to accommodate the depth of a wall cavity as shown in  FIG. 5 . As shown in the cross-section of  FIG. 4 , locking tab  60  is folded over the outer end  46  of support plate  14  to effectively lock extension plate  16  in an extended position with respect to support plate  14 . As shown in  FIG. 5 , extension plate  16  effectively increases the length of support plate  14  to engage the opposing wall  72  to prevent flexing of the front plate  12  and movement of the electrical box during use. 
     Referring to  FIG. 6 , wall stud  26  can have a dimension indicated by arrow  78  that is less than the dimension  76  of wall stud  26  of  FIG. 5 . The wall stud  26  shown in  FIG. 6  having the dimension indicated by arrow  78  forms a wall cavity having a dimension less than the combined length of support plate  14  and extension plate  16  when folded to the extended position. As shown in  FIG. 6 , extension plate  16  can be folded along one of the fold lines  56  to effectively shorten the length of extension plate  16  so that the folded portion of the extension plate contacts the opposing wall  72  while it supports front plate  12  in a position substantially parallel to opposing wall  72 . 
     In the embodiment of  FIGS. 1-6 , mounting bracket  10  is able to accommodate wall structures having different cavity depths by folding the extension plate outwardly and where necessary folding the extension plate about the fold lines to reduce the overall length of the support plate and extension plate. In one preferred embodiment, support plate  14  has a length corresponding to the minimum depth of a standard wall structure which can be, for example, about 3.5 inches. In wall structures having a depth greater than the length of the support, the extension plate is folded outward and locked into place so that the end of the extension plate can contact the opposing wall. In the event the depth of the wall cavity is less than the combined length of the support plate and the extension plate, the effective length of the extension plate can be reduced by folding along one or more of the fold lines. The resulting tab formed by folding the extension plate along the fold line can be folded 90° as shown in the drawings or folded 180° to lay flat against the support plate or extension plate. 
     The locking tab as shown in the illustrated embodiment is integrally formed with the structure and folded over to clamp the extension plate in the extended position with respect to the support plate. In the illustrated embodiment, the locking tab is cut from the extension plate and positioned to fold over the outer end of the support plate. In alternative embodiments, the locking tab is formed with the support plate which can be folded over the extension plate to lock the extension plate in the extended position. In another embodiment, a separate fastener, clip or locking member can be coupled to the extension plate and/or support plate to lock the extension plate in the extended position. 
     Embodiment of FIGS.  7 - 13   
     In a second embodiment of the invention, a mounting bracket  90  is formed from a cut or stamped blank of sheet material as shown in  FIG. 7 . Mounting bracket  90  includes a front plate  92  defining a front mounting panel, a support plate  94  and an extension plate  96 . As shown in  FIG. 7 , front plate  92 , support plate  94  and extension plate  96  are integrally formed and connected together by fold lines as discussed hereinafter in greater detail. 
     Front plate  92  includes a front face  98  and a side portion  100  connected to front face  98  by a stepped portion  102  to offset front face  98  with respect to side portion  100 . Side portion  100  includes a plurality of holes  104  for receiving fasteners to attach side portion  100  to a wall stud or other support surface. Front face  98  includes a plurality of holes  106  for receiving fasteners for coupling an electrical box to front mounting plate  92 . 
     Support plate  94  and extension plate  96  are cut from the blank and bent outwardly from front plate  92  as shown in  FIG. 9  to form a central opening  108 . Central opening  108  has a dimension to accommodate the electrical box  110  and defines first and second side sections  112  and  114 . A top section  116  and a bottom section  118  extend between side sections  112  and  114  as shown in  FIG. 9 . 
     Support plate  94  is connected to the inner edge  120  of central opening  108  alongside section  114 . Elongated slots  122  define a fold line between side section  114  and support plate  94  as shown in  FIG. 7 . Support plate  94  includes a central opening  124  to define a pair of legs  126  and an outer end portion  128 . Embossed ribs  130  are formed along the length of legs  126  to strengthen legs  126  during use. Outer end portion  128  has an outer edge  132 . 
     Extension plate  96  is integrally formed with support plate  94  and coupled to outer edge  132  of extension plate  96 . Elongated slots  134  are formed to define a fold line  136  between support plate  94  and extension plate  96 . Extension plate  96  in this embodiment includes an end portion  138  and a pair of legs  140  extending from end portion  138 . Legs  140  are cut from the blank adjacent legs  126  of support plate  94  as shown in  FIG. 7 . End portion  138  is connected to support plate  94  along fold line  136 . End portion  138  includes an edge  140  having a locking tab  144  cut from end portion  138 . Locking tab  144  is connected to end portion  138  by a fold line  146  and includes side edges  148  and an outer edge  150 . 
     In use, mounting bracket  90  is folded to the position shown in  FIG. 9  where support plate  94  is substantially perpendicular to front plate  92  and extension plate  96  is folded with respect to support plate  94  to be substantially parallel with front plate  92  and perpendicular to support plate  94 . Bending support plate  94  and extension plate  96  forms central opening  108  as shown in  FIG. 9  to allow the electrical box  110  to be coupled to front plate  92  and to allow access to the interior of electrical box  110 . As shown in  FIG. 10 , side portion  100  of front plate  92  is attached to a wall stud  152  by suitable fasteners such as nails or screws. As in the previous embodiment, wall stud  152  supports a front wall (not shown) and an opposing wall  154  as shown in  FIG. 10 . As shown in  FIG. 10 , support plate  94  has a length substantially equal to the dimension of wall stud  152 . In this manner, the outer edge  132  of support plate  94  and the face of extension plate  94  contact opposing wall  154  to support the end of mounting bracket  90  and prevent bending or flexing of front plate  92  with respect to side portion  100  and wall stud  152 . 
     As in the previous embodiment, mounting bracket  90  is able to accommodate a wall cavity having different depths and dimensions. Referring to  FIG. 11 , extension plate  96  is folded along fold line  136  so that extension plate  96  is substantially parallel to support plate  94 . As shown in  FIG. 12 , locking tab  144  is folded along fold line  146  over the inner edge of outer end portion  128  to secure extension plate  96  in an extended position with respect to support plate  94 . As shown in  FIG. 13 , the combined length of support plate  94  and extension plate  96  complements the dimension of wall stud  152  so that an outer end  156  of legs  140  contact opposing wall  154  to support mounting bracket  90 . As in the previous embodiment, legs  140  include a plurality of spaced-apart fold lines so that the effective length of extension plate  96  can be shortened to accommodate the dimension of the wall cavity defined by the opposing wall  154  and wall stud  152  by bending legs  140  along the selected fold line  158 . The extension plate  96  is shortened in a manner similar to the previous embodiment by folding along the fold lines  158 . The resulting tab can be folded to be perpendicular to the extension plate or folded parallel to the extension plate. 
     While various embodiments have been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made without departing from the scope of the invention as defined in the appended claims.