Patent Publication Number: US-2023138590-A1

Title: Non-fan ceiling junction box

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Application 63/274,336 filed Nov. 1, 2021, the entire contents of which are incorporated by reference herein. 
    
    
     BACKGROUND 
     1. Field of the Invention 
     The present disclosure is related to junction boxes. More particularly, the present disclosure is related to non-fan rated ceiling junction box assemblies, as well as junction boxes and electrical devices for use with such assemblies. 
     2. Description of Related Art 
     Electrical junction boxes are typically installed in walls and ceilings. Electrical conductors can be run from the service panel through the walls and/or ceilings so as to terminate in a junction box. An electrical device can be operatively coupled with the electrical conductor in the junction box in a known manner. 
     When installed in a ceiling, the junction box can be exposed to differing levels of forces imparted by the electoral device. 
     Some ceiling junction boxes are configured for support of electrical devices that generally impart only a vertical load and/or static load to the junction box—namely impart only light-duty forces to the junction box. These junction boxes are often secured to only one ceiling joist. For ease of discussion, this type of junction box is referred to herein as “light-duty” and/or “non-fan rated”. 
     Other ceiling junction boxes are configured for support of electrical devices imparting heavier vertical loads and/or imparting dynamic forces such as rotational forces to the junction box. For example, these junction boxes can be operatively connected to electrical devices such as, but not limited to, ceiling fans, combined fan/lighting devices, high weight chandeliers, and other high load imparting devices. These junction boxes are often secured to two adjoining ceiling joists. For ease of discussion, this type of junction box is referred to herein “heavy-duty” and/or “fan rated” 
     The fan-rated ceiling junction boxes are typically more expensive to purchase and install then the non-fan rated ceiling junction boxes. Thus, it is common for builders to minimize construction costs by installing only the less expensive non-fan rated ceiling junction boxes—in combination with an electrical device that imparts light-duty forces. 
     Home owners looking to upgrade from the builder installed light-duty electrical device to a heavier electrical device such as a chandelier and/or to a ceiling fan can inadvertently install these devices onto the “light-duty” and/or “non-fan rated” ceiling junction box. 
     Accordingly, it has been determined by the present disclosure that there is a need for non-fan rated ceiling junction boxes and related assemblies that overcome, alleviate, and/or mitigate one or more of the aforementioned and other deleterious effects of the prior art. 
     SUMMARY 
     A non-fan rated ceiling junction box is provided. The junction box includes a main body, an outlet, and fasteners that connect the outlet in the main body. The fasteners have a feature selected from a group consisting of: non-removable, removable only using a non-standard tool, inaccessible without a special tool, positioned on the main body so as to be inaccessible when installed, and any combinations thereof. 
     An electrical light fixture is also provided. The fixture includes a light fixture, a male plug, a conduit coupling the male plug to the light fixture, and a cover portion. The cover portion is on the conduit between the light fixture and the male plug. The cover portion has one or more fasteners that connect the cover portion to a ceiling junction box with the plug remaining between the cover and the ceiling junction box. 
     A non-fan rated ceiling junction box assembly is provided. The assembly includes a non-fan rated ceiling junction box and a light fixture. The junction box has an outlet secured therein by first fasteners. The light fixture has a conduit operatively coupling a male plug to the light fixture and has a cover portion. The cover portion is positioned on the conduit between the light fixture and the male plug. The cover portion has second fasteners that connect the cover portion to the non-fan rated ceiling junction box while the plug is operatively coupled in the outlet. 
     In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the first fasteners have a feature selected from a group consisting of: non-removability, removable only using a non-standard tool, inaccessible without a special tool, positioned on the main body so as to be inaccessible when installed, and any combinations thereof. 
     The above-described and other features and advantages of the present disclosure will be appreciated and understood by those skilled in the art from the following detailed description, drawings, and appended claims. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       The sole FIGURE is a perspective view of an exemplary embodiment of a non-fan rated ceiling junction box assembly according to the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The sole FIGURE illustrates an exemplary embodiment of a non-fan rated ceiling junction box assembly according to the present disclosure, which is generally referred to by reference numeral  10 . Assembly  10  includes a non-fan rated ceiling junction box  12  and an electrical device  14 . Advantageously, assembly  10  is specifically configured to prevent installation of heavy-duty electrical devices in the manner discussed in detail below. 
     Box  12  has a main body  16 , one or more mounts  18 , and an electrical outlet  20 . Main body  16  can have any desired shape or size as known in the art. In the illustrated embodiment, box  12  is illustrated as a molded plastic member having body  16  and mounts  18  formed as unitary members to one another. Of course, it is contemplated by the present disclosure for box  12  to have any known configuration. Further, box  12  can be made of any desired material including, but not limited, to polymers, metals, and combinations thereof. 
     Box  12  can be secured to a joist (not shown) using mounts  18  and first fasteners  22 , which are illustrated as nails. Of course, it is contemplated for box  12  to be secured to the joist or other structural member in any desired manner. In the illustrated embodiments, mounts  18  are shown as shoulders extending from main body  16 . However, it is contemplated by the present disclosure for mounts  18  to be as simple as openings in a wall of main body  16  that receive first fasteners  22 . 
     Outlet  20  is positioned in box  12  and secured on position one or more second fasteners  24 . When installed, and operatively coupled to an electrical conductor (not shown) in a known manner. 
     Electrical device  14  includes a cover portion  26 , a male plug  28 , and a conduit  30  operatively coupled to a light fixture  32  (shown schematically). Cover  26  and plug  28  are sized, positioned, and configured so that the plug can be operatively coupled to outlet  20  with cover  26  secured to box  12 . 
     Cover  26  includes one or more openings  34  that can be placed into registration with one or more openings  36  in box  12  so as to receive one or more third fasteners  38 . In the illustrated embodiment, openings  36  are positioned in a face  40  of outlet  20 . Of course, it is contemplated by the present disclosure for openings  36  to be defined in any portion of box  12  such as in main body  16 , mounts  18 , or outlet  20 . 
     In this manner, assembly  10  is configured—through the configuration of box  12  having outlet  20  and electrical device  14  having plug  28 —to prevent installation of heavy-duty electrical devices by the typical homeowner. For example, if the homeowner were to purchase another electrical device (i.e., fan, chandelier, or even another light fixture) that device would lack plug  28  and would require more extensive work/modification in order to be installed. 
     In some embodiments, assembly  10  is configured so that outlet  20  can be secured in box  12  in a manner that makes removal difficult for the typical homeowner and/or prevents connection of electrical devices other than those having plug  28 . 
     In one embodiment, assembly  10  can be provided with second fasteners  24  that require a special tool to allow removal of outlet  20  from box  12 . 
     In another embodiment, assembly  10  can be provided with second fasteners  24  that are non-removable without damage to or destruction of the second fasteners  24  and/or outlet  20 . 
     In yet another embodiment, assembly  10  can be configured so that second fasteners  24  are hidden by or inaccessible through the material of the ceiling (e.g., drywall) that is installed after positioning of the outlet in the box. 
     In still other embodiments, assembly  10  can be configures so that outlet  20  is secured in box  12  using a mechanical connection that is inaccessible without a special tool—or where the mechanical connection is frangible such that removal of outlet  20  prevents reassembly of box and/or outlet. 
     In further other embodiments, assembly  10  is configures to that box  12  lacks any threaded bosses that are typically required for installation of other electrical devices. 
     Regardless of the type or manner of connection between box  12  and outlet  20 , the means of connection is designed to at a minimum increase the difficulty with which outlet  20  is removed from the box, but can also entirely prevent removal or eliminate any means from box  12  that allows connection with other electrical devices. 
     Assembly  10  can be configured so that, when outlet  20  and plug  28  are connected, the connection therebetween can support the weight of electrical device  14  prior to securement of cover  26  to box  12  by third fasteners  38 . In this manner, assembly  10  is configured to ease the assembly of box  12  and electrical device  14  by allowing the user to first insert plug  28  into outlet  20 —then connect cover  26  using third fasteners  38  without having to deal with supporting electrical device  14  while positioning cover  26 , aligning or registering openings  34 ,  36 , and installing third fasteners  38 . 
     In some embodiments, outlet  20  and plug  28  can form a twist connection that is sufficient to support the weight of electrical device  14 . In other embodiments, face  40  of outlet  20  can have a member (not shown) that is movable with respect to the outlet so that, once plug  28  is installed in outlet  20 , the member can be moved to interfere with the removal of the plug from the outlet. 
     Electrical device  14  can be configured so that cover  26  is movable along conduit  30  and/or rotatable about the conduit. In this manner, cover  26  can be moved away from plug  28  to allow clearance to install the plug into outlet  20  without interference by the cover. Once plug  28  is installed in outlet  20 , cover  26  can be moved along conduit  30  towards box  12  and the cover can be rotated about the conduit to align or register openings  34  on the cover to openings  36  on box  12  to allow installation of third fasteners  38 . 
     In other embodiments, assembly  10  can be configured so that cover  26  forms a mechanical connection directly to box  12 . Here, openings  34 ,  36  and third fasteners  38  can be eliminated—and replaced with a mechanical connection (not shown) on inside of cover  26  that mates with a corresponding connection (also not shown) on box  12 . Suitable mechanical connections contemplated by the present disclosure include, but are not limited to, corresponding threads on the interior of cover  26  and exterior of main body  16 , movable tabs on the interior of cover  26  and corresponding slots on the exterior of box  12  (i.e., main body  16  and/or cover  40 ), and others. 
     It has also been found that assembly  10  affords additional flexibility and utility during construction and personalization of the user space. For example in traditional construction with prior art ceiling boxes and light fixtures, the electrician first installs the junction box and runs the electrical conduit to the junction box, followed by installation of drywall over the junction box to close the ceiling, followed by painting, with the electrician having to return to the site to install the light fixture. Advantageously, assembly  10  allows the electrician to install junction box  12  and wire outlet  20  to the electrical conduit. Final installation of electrical device  14  can be handled by trades outer than the electrician as it merely requires insertion of plug  28  into outlet  20 . 
     It should also be noted that the terms “first”, “second”, “third”, “upper”, “lower”, and the like may be used herein to modify various elements. These modifiers do not imply a spatial, sequential, or hierarchical order to the modified elements unless specifically stated. 
     While the present disclosure has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment(s) disclosed as the best mode contemplated, but that the disclosure will include all embodiments falling within the scope of the appended claims. 
     PARTS LIST 
     non-fan rated ceiling junction box assembly  10   
     non-fan rated ceiling junction box  12   
     electrical device  14   
     main body  16   
     mounts  18   
     electrical outlet  20   
     first fasteners  22   
     second fasteners  24   
     cover portion  26   
     male plug  28   
     conduit  30   
     light fixture  32   
     cover openings  34   
     box openings  36   
     third fasteners  38   
     outlet face  40