Patent Abstract:
A supporting structure, including a bracket brace and a bracket is disclosed. Preferably, the brace has an inside section and an outside section that move relative to each other. A portion of the inside section can be positioned completely within the outside section and each of the inside and outside sections have a pair of vertical portions. The brace also has a slot extending through the inside and outside sections. The bracket is coupled to the inside section of the brace and to each of the vertical portions of the outside sections of the brace. The bracket also has a coupling members in the form of threaded openings to secure a supported member; such as an electrical junction box, against the brace to prohibit relative movement between the brace and the bracket. The brace and bracket allow new, heavier lighting fixtures and ceiling fans to be safely supported.

Full Description:
This application is a continuation-in-part of U.S. patent application Ser. No. 09/040,935, filed Mar. 19, 1998, the contents of which are incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The invention relates generally to a mounting bracket and a supporting brace. More specifically, the invention relates to a bracket for supporting a fixture of a ceiling fan. The bracket can be attached to a brace; such as a telescoping brace, and provide both a locking mechanism and structural reinforcement for the brace. 
     BACKGROUND OF THE INVENTION 
     Presently, the National Electrical Code permits ceiling light fixtures up to 50 pounds and ceiling fans up to 35 pounds. However, impending changes to the code will increase the acceptable weight of ceiling light fixtures to 80 pounds and the acceptable weight of ceiling fans to 70 pounds. Although various supports for supporting outlet boxes have been developed, the prior art devices were not designed for supporting the increased loading associated with the heavier lighting fixtures and ceiling fans. Thus, there is a need in the art for structures capable of supporting the heavier lighting fixtures and ceiling fans, especially structures that can be positioned between joists. 
     Examples of prior art supporting structures are disclosed in the following U.S. Pat. Nos.; 2,925,236 to Cook et al.; 2,945,661 to Appleton; 3,214,126 to Roos; 3,518,421 to Cogdill; 4,037,098 to Kowalski; to 4,050,603 to Harris et al.; 4,538,786 to Manning; Re. 33,147 to Reiker, 4,909,405 to Kerr, Jr.; 5,044,582 to Walters; and 5,303,894 to Deschamps et al. 
     Thus, there is a continuing need to provide an improved supporting structure, especially for supporting lighting fixtures and ceiling fans weighing up to 80 pounds and 70 pounds, respectively. This invention addresses these needs in the art as well as other needs, which will become apparent to those skilled in the art once given this disclosure. 
     SUMMARY OF THE INVENTION 
     One object of the present invention is to provide an improved supporting structure. 
     Still another object of the invention is to provide a structure for supporting lighting fixtures and ceiling fans, or electrical boxes for supporting fixtures and fans. 
     Yet another object of the invention is to provide a structure for supporting lighting fixtures and ceiling fans, which are heavier than previously permitted. 
     A further object of the invention is to provide a bracket for reinforcing a brace. 
     Still a further object of the invention is to provide a bracket for reinforcing and locking a telescoping brace. 
     The foregoing objects are basically attained by providing a bracket comprising: a first portion having a first central axis in a first plane and a second central axis extending substantially perpendicular to the first central axis and being in a second plane, first and second sides, each of the first and second sides being spaced from the first central axis and facing outwardly from the first central axis, the first side facing in a first direction substantially perpendicular to the first central axis and the second side facing in a second direction substantially perpendicular to the first central axis and substantially parallel to and opposite to the first direction, the first plane being positioned between the first and second sides, and a third side facing in a third direction substantially perpendicular to both the first and second central axes, the first portion further having a coupling element adapted to attach the bracket to a supported element; and a first extension coupled to the first portion and having fourth and fifth sides, each of the fourth and fifth sides being spaced from the first central axis and facing inwardly toward the first central axis, the fourth side facing in the second direction and the fifth side facing in the first direction, and a sixth side facing in a fourth direction substantially parallel to and opposite to the third direction, the first and fourth sides being separated from the second and fifth sides by the first plane, the sixth side being spaced further from the first central axis than the third side in the third direction, and the first portion and the first extension being integrally formed as a one-piece, unitary member. 
     The foregoing objects are also attained by providing supporting structure, comprising: a brace having an inside section, an outside section with a pair of vertical portions, and a slot extending through the inside and outside sections; a bracket coupled to the inside section of the brace and to each of the vertical portions of the outside section; and a coupling member attached to the bracket and adapted to secure a supported member against the brace to prohibit relative movement between the brace and the bracket. 
     The foregoing objects are rather attained by providing a supporting structure, comprising a brace having a hollow, elongated member with a longitudinal axis, an inside section, an outside section, and an elongated slot extending through the inside and outside sections; and a bracket having a first portion positioned within the elongated member and being directly connected to the inside section of the elongated member and a first extension attached to the first portion, extending through the elongated slot, and being directly connected to the outside section of the elongated member, the first portion and the first extension being integrally formed as a one-piece, unitary member, and the first portion further having a coupling element adapted to attach the bracket to a supported element. 
     The foregoing objects are further attained by providing a supporting structure, comprising: a brace having a hollow, elongated member with a longitudinal axis, an inside section with a horizontal bottom, an outside section with first and second vertical sides, and an elongated slot extending through the inside and outside sections; and a bracket having a first portion with first and second ends and a base, the first portion positioned within the elongated member and the base directly abutting the bottom of the brace, the bracket further having first and second extensions attached to the first and second ends of the first portion, respectively, the first extension being spaced from the second extension in a direction substantially parallel to the longitudinal axis, each of the first and second extensions extending through the elongated slot and having a pair of vertical stiffeners, one of the stiffeners of each of the pair of stiffeners directly abutting the first vertical side of the brace, and another of the stiffeners of each of the pair of stiffeners directly abutting the second vertical side of the brace, and the first portion further having a coupling element adapted to attach the bracket to a supported element 
     The foregoing objects are still firer attained by providing a supporting structure, comprising: a brace having a hollow, elongated member with a longitudinal axis, an inside section, an outside section, and an elongated slot extending through the inside and outside sections; and a bracket having a first portion positioned within the elongated member and being directly connected to the inside section of the elongated member and a first extension attached to the first portion, the first extension extending through the elongated slot and being directly connected to the outside section of the elongated member, the first portion further having a plurality of coupling elements adapted to attach the bracket to a supported element, each of the plurality of coupling elements being spaced in a first direction substantially parallel to the longitudinal axis. 
     Other objects, advantages, and salient features of the invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses preferred embodiments of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Referring now to the attached drawings which form a part of this original disclosure. 
     FIG. 1 is a side elevational view of a brace and a bracket in accordance with the present invention, which is positioned between joists and is supporting an electrical junction box; 
     FIG. 2 is an enlarged, partial view of FIG. 1 illustrating the brace and bracket in accordance with the present invention, supporting a junction box; 
     FIG. 3 is a cross-sectional view of the brace and bracket in accordance with the present invention supporting a junction box, taken along line  3 — 3  of FIG. 2; 
     FIG. 4 is a top-side perspective view of the bracket in accordance with the present invention within one of the telescoping channels of the brace in accordance with the present invention; 
     FIG. 5 is a top-front-side perspective view of the bracket in accordance with the present invention; 
     FIG. 6 is a front elevational view of the bracket in accordance with the present invention; 
     FIG. 7 is a side elevational view of the bracket in accordance with the present invention; 
     FIG. 8 is a bottom-front-side perspective view of the bracket in accordance with the present invention; 
     FIG. 9 is a bottom view of the bracket in accordance with the present invention; 
     FIG. 10 is a cross-sectional view of the bracket in accordance with the present invention taken along line  10 — 10  of FIG. 9; 
     FIG. 11 is a plan view of an unfolded blank used to form the bracket in accordance with the present invention; 
     FIG. 12 is a front view of one of the channels of the brace in accordance with the present invention; 
     FIG. 13 is a side elevational view of one of the channels of the brace in accordance with the present invention; 
     FIG. 14 is a bottom view of one of the channels of the brace in accordance with the present invention; 
     FIG. 15 is a plan view of an unfolded blank used to form one of the channels of the brace in accordance with the present invention; 
     FIG. 16 is a side elevational view of one of the channels of the brace in accordance with the present invention located in a first position with respect to a section of wall board; 
     FIG. 17 is a side elevational view of one of the channels of the brace in accordance with the present invention located in a second position with respect to a section of wall board; 
     FIG. 18 is a side elevational view of one of the channels of the brace in accordance with the present invention located in a third position with respect to a section of wall board; 
     FIG. 19 is a top-front-side perspective view of the bracket in accordance with a second embodiment of the present invention; 
     FIG. 20 is a front elevational view of the bracket in accordance with the second embodiment of the present invention; 
     FIG. 21 is a side elevational view of the bracket in accordance with the second embodiment of the present invention; 
     FIG. 22 is a cross-sectional view of the brace and bracket similar to FIG. 3, but in accordance with the second embodiment of the present invention supporting a junction box; 
     FIG. 23 is a top-side perspective view of the bracket in accordance with the second embodiment of the present invention within one of the telescoping channels of the brace in accordance with the present invention; 
     FIG. 24 is a top view of the bracket in accordance with the third embodiment of the present invention; 
     FIG. 25 is a cross-sectional view of the bracket in accordance with the third embodiment of the present invention taken along line  25 — 25  of FIG. 24; and 
     FIG. 26 is a side elevational view of the bracket in accordance with the third embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     As seen in FIG. 1, a supporting structure  10  in accordance with the present invention is illustrated. Although supporting structure  10  can be use to support various apparatus, it preferably supports an electrical junction box  12  attached to a ceiling fan or lighting fixture  14 . 
     Supporting structure  10  includes a brace  20  that is positioned between two joists  22  and a bracket  24 . Junction box  12  is secured to bracket  24  and the location of supporting structure  10  on joists  22  permits junction box  12  to extend through an opening  25  in wall board  26 . 
     Brace  20  has two telescoping channels  40  and  42 . Channels  40  and  42  are substantially identical to each other except that channel  40  is dimensioned smaller than channel  42 . This permits channel  40  to be received within channel  42  in a telescoping manner, i.e., channel  40  can move relative to channel  42  while being inserted within channel  42 . This feature enables brace  20  to be positioned between joists  22  that are spaced various distances apart. Thus, one brace  20  can be made to accommodate a variety of joist spacing. 
     Since channels  40  and  42  are substantially identical, only channel  42  will be described in detail. Channel  42  has a telescoping end  44  and an attaching end  46 , and extends along a longitudinal axis  47 . Although channels  40  and  42  can take various shapes, telescoping end  44  has a substantially planar top  48 , two substantially planar sides  50 , and a substantially planar bottom  52  with an elongated slot  54  extending completely through bottom  52 . Each of sides  50  are substantially parallel and are substantially perpendicular to top  48  and to bottom  52 . Top and bottom  52  are substantially parallel to each other and are substantially perpendicular to sides  50 . Additionally, each side  50  has an outer vertical surface  51 , and each bottom  52  has a lower horizontal surface  53 . 
     Attaching end  46  has a plate  60  and holes  62  extending therethrough to receive mounting fasteners  64 ; such as, mounting screws. Mounting screws  64  rigidly couple brace  20  to joists  22  as is known in the art. Once channels  40  and  42  are rigidly secured to joists  22 , channels  40  and  42  are prohibited from moving relative to each other. Preferably, mounting screws  64  are one inch long  12 - 14  type AB threaded tapping screws. A tab  66  extends from the bottom of plate  60  to aid in the positioning of brace  20  relative to wall board  26 . 
     Since brace  20  can accommodate junction boxes of various shapes and sizes, brace  20  must be capable of being placed at various distances from wall board  26  when junction boxes of various depths are used. As seen in FIGS. 16, if a deep junction box  12 ; for example, 2⅛ inches deep, is used with brace  20 , tab  66  can be spaced from wall board  26  to accommodate this specific junction box. Additionally, tab  66  can be specifically sized to correspond to a junction box  12  of a specific depth. For instance, if a junction box having a depth of 1½ inches is used, tab  66  can be sized so that brace  20  can be positioned such that the bottom of tab  66  is flush against wall board  26 . This facilitates placement of brace  20  on joists  22  for certain sized boxes. Further, tab  66  can aid in the placement of brace  20  when more shallow junction boxes  12  are used. For example, junction boxes  12  that are ½ inch deep. In particular, a score  70  positioned where tab  66  meets plate  60 , enables tab  66  to be broken and separated from plate  60 . Then, channel  42  can be placed flush against wall board  26 . 
     Tab  66  also has a nailing spur  72  that can be hammered into joist  22  to temporarily support plate  60  against joist  22  while securing plate to joist  22  with mounting screws  64 . 
     As seen in FIG. 3, channel  40  has a top  78 , two sides  80 , and a bottom  82  with an elongated slot  84  extending therethrough. Also, each side  80  has an inner vertical surface  81 . Channel  40  is substantially identical to channel  42 , except that the sizes and spacing of top  78 , sides  80 , and bottom  82  are changed to allow channel  40  to easily slide within channel  42 . As seen in FIG. 3, when channel  40  is positioned within and received by channel  42 , that portion of channel  40  within channel  42  is completely received within channel  42 . 
     Channels  40  and  42  are each preferably formed by being folded from a single, unitary member, for example, by being folded from a single, substantially flat blank of material. Blank  90 , as seen in FIG. 15, can be folded to form channel  42 . Since channels  40  and  42  are substantially identical as discussed above, the blank used to form channel  40  is substantially identical to blank  90 , except that the width of the blank may be less than that of channel  42 , to form the smaller top  78 , sides  80 , and bottom  82 . The same blank  90  can be use for both channels  40  and  42 , if channel  40 , i.e., the smaller channel, is folded differently to enable it to be inserted into channel  42 . The different fold for channel  40  would also vary as a result of the different folding. The general use of and folding of blanks to form structures is known in the art. Although any number of materials can be used, preferably, blank  90  is a metallic material; such as galvanized 0.039 sheet steel. 
     Bracket  24  has a main portion  100 , two extensions  102 , a longitudinal axis  104  in a vertical plane  105 , and a transverse axis  106  in a horizontal plane  107 . Main portion  100  has a top  110  and two pairs of substantially parallel and opposite sides  112 . Top  110  is substantially planar and has two, opposite ends  114  spaced along longitudinal axis  104 . Each side  112  is substantially perpendicular to top  110  and has a vertical surface  113  facing away from longitudinal axis  104  in a direction that is substantially parallel to transverse axis  106 , and a lower horizontal surface  115  facing downwards. Main portion  100  also has coupling elements  116  for connecting with junction box  12  or a fan or fixture bracket. Coupling elements are preferably threaded holes for receiving box mounting screws  118 , although they can be any device to capture the fastening device used to secure junction box  12  to bracket  24 . Preferably, two holes  116  are used to provide a more secure and rigid connection between junction box  12  and bracket  24 . Further, box mounting screws  118  are preferably ¾ inch long 12-24 screws with a lockwasher  120  as seen in FIG.  1 . 
     Holes  116  are preferably extruded. Although holes  116  are illustrated as extending downwardly in the direction of extensions  102  in, for example, FIG. 6, it may be preferred to form holes  116  extending upwardly, in a direction away from extensions  102  and opposite to the direction illustrated in FIG.  6 . 
     Extensions  102  are located at each end  114  of main portion  100 . Each extension  102  has an inclined narrow strip  124  that attaches to a bottom  126 , which is substantially planar. Preferably, the inclination of strip  124  relative to longitudinal axis  104  is approximately 45 degrees. Each bottom  126 , in turn, has two substantially parallel sides  128 , which are substantially perpendicular to bottom  126  and extend upwardly. Bottom  126  has an upper horizontal surface  130  and each side  128  has an inner vertical surface  134 , each facing each other. 
     Bracket  24 , like brace  20  is preferably formed by being folded from a single, unitary member, for example, a substantially flat blank  140  of material. Blank  140 , as seen in FIG. 11, can be folded to form bracket  24  in a manner similar-to the folding of channels  40  and  42 .. Preferably, blank  140  is a metallic material; such as galvanized 0.0625 sheet steel. Thus, blank  140  for bracket  24  is thicker than blank  90  for channels  40  and  42 . 
     Bracket  24  is sized to fit inside channel  40  in order to act as a lock to stop relative movement of bracket  24  and channels  40  and  42 , while also extending outside channel  42  to help prevent sides  50  from spreading outwardly due to increased downward loading by ceiling fan or lighting fixture  14 . The location of extensions  102  against the outer vertical surfaces  51  provides the mechanism for prohibiting sides of channels  40  and  42  from spreading apart. Additionally, since bracket  24  can be positioned anywhere along brace  20 , this reinforcement of channels  40  and  42  travels to the area of brace  20  where it is needed most. 
     Accordingly, the distance between outer vertical surfaces  113  of main portion  100  is slightly less than the distance between inner vertical surfaces  81  of channel  40 . Additionally, the distance between inner vertical surfaces  134  of each extension  102  is slightly greater than the distance between outer vertical surfaces  51  of channel  42 . Bracket  24  is sized to easily, but snugly fit with inner channel  40 , and to easily, but snugly receive outer channel  42 . 
     Also, although main portion  100  of bracket  24  is spaced along longitudinal axis  104  from extensions  102 , the horizontal dimensions of these elements are related to each other to permit insertion of bracket  24  into channel  40  and to permit the insertion of channel  40  and bracket  24  into channel  42 . In particular, each lower horizontal surface  115  of main portion  100  and each upper horizontal surfaces  130  of extensions  102  are spaced a distance slightly greater than the combined thickness of bottoms  82  and  52  of channels  40  and  42 , respectively, in a direction substantially perpendicular to longitudinal axis  104 . 
     The spacing of extensions  102  along longitudinal axis  104  is also important. As seen in FIGS. 1 and 2, extensions  102  are spaced apart a distance greater than the width of junction box  12 . This enables the top  150  of junction box  12  to directly abut lower horizontal surface  53  of channel  42 , or the bottom  82  of channel  40 , or portions of both surface  53  of channel  42  and bottom  82  of channel  40 , depending on how bracket  24  is situated with respect to each channel  40  and  42 . Then, upon the tightening of box mounting screws  118 , bottoms  82  and  52  of channels  40  and  42  are sandwiched between surfaces  115  of sides  112  of bracket  24  and top  150  of junction box  12 . Thus, not only is junction box  12  securely and rigidly connected to bracket  24  and brace  20 , but bracket  24  is prohibited from moving relative to channels  40  and  42 , and is securely and rigidly fixed in a single position. This allows the once adjustable brace  20  and bracket  24  to become a rigid supporting structure  10  for junction box  12 . 
     The structure and function of junction box  12  is known in the art and therefore will not be described here in great detail. Junction box  12  preferably has mounting screws  152  for mounting lighting fixture or ceiling fan  14  securely thereto. Junction box  12  can be any known junction box; such as that described in U.S. Pat. No. 4,892,211 to Jorgensen. Accordingly, U.S. Pat. No. 4,892,211 to Jorgensen is hereby incorporated herein by reference. 
     Although supporting structure  10  has many uses, preferably it is used as follows. Main portion  100  of bracket  24  is positioned within channel  40  as seen in FIG.  4 . Main portion  100  of bracket  24  and channel  40  are then inserted into telescoping end  44  of channel  42  so that extensions  102  of bracket  24  remain outside channel  42  as seen in FIG.  3 . At this point, channels  40  and  42  and bracket  24  are snugly interconnected while each is capable of easily moving relative to each in a direction substantially parallel to longitudinal axis  47 . 
     Junction box  12  is then loosely connected to bracket  24  by mounting screws  118 . Supporting structure  10  is then placed between two joists  22  and channels  40  and  42  are moved relative to each other so that each attaching end  46  and  76  of channels  42  and  40  can abut a joist  22 . The depth of junction box  12  being known, tab  65  is either removed or left in place and the positioning of brace  20  relative to wall board  26  is accomplished in one of the orientations illustrated FIGS. 16-18. Channels  40  and  42  are then rigidly secured to joists  22  by mounting screws  64 . 
     Once channels  40  and  42  are secured to joists  22 , they do not normally move relative to each other, however, bracket  24  is capable of moving relative to each of the fixed channels  40  and  42 . This enables the precise positioning of bracket  24 , where desired. Then, junction box  12  is rigidly secured to mounting bracket  24  by tightening box mounting screws  118 . Upon tightening screws  118 , top  150  of junction box  12 , bracket  24 , and either one or both of channels  40  and  42  are compressed together to form a rigid assembly. Thus, bracket  24  and junction box  12  are rigidly fixed with respect to channels  40  and  42  and joists  22 . 
     Although bracket  24  is illustrated and described as being used with telescoping channels  40  and  42  and supporting either a ceiling fan or a lighting fixture  14 , it should be understood that bracket  24  can be used with structures other than telescoping channels, and can support apparatus other than ceiling fans and lighting fixtures For example, bracket  24  can be used with a single, fixed channel and can support any appropriately sized item intended to be supported by that fixed channel. 
     Additionally, bracket  24  can be positioned anywhere along channels  40  and  42 . For example, bracket  24  can be positioned entirely on channel  40 , or entirely on channel  42 , or partly on one of channels  40  and  42  and partly on the other of channels  40  and  42 , or entirely on both channels  40  and  42  simultaneously, providing there exists sufficient overlap. 
     While an advantageous embodiments have been chosen to illustrate the invention, it will be understood by those skilled in the art from this disclosure that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims. 
     FIGS. 19-23 illustrate a second embodiment of the present invention, in the form of bracket  224 . Bracket  224  is substantially identical to bracket  24  except for the absence of sides  112  and the shallower inclination of strips  1124  to accommodate the absence of sides  112 , as seen in FIG.  22 . Bracket  224  has the advantage of being lighter, less expensive, and easier to make than bracket  24 , yet substantially strong to satisfy the appropriate UL testing. 
     Bracket  224  has a main portion  1100 , two extensions  1102 , a longitudinal axis  1104  in a vertical plane  1105 , and a transverse axis  1106  in a horizontal plane  1107 . Main portion  1100  has a top  1110  which is substantially planar and has two, opposite ends  1114  spaced along longitudinal axis  1104 . Main portion  1100  also has coupling elements  1116  for connecting with junction box  12  or a fan or fixture bracket. Coupling elements are preferably threaded holes for receiving box mounting screws  118 , although they can be any device to capture the fastening device used to secure junction box  12  to bracket  24 . Preferably, two holes  1116  are used to provide a more secure and rigid connection between junction box  12  and bracket  24 . 
     Extensions  1102  are located at each end  1114  of main portion  1100 . Each extension  1102  has an inclined narrow strip  1124  that attaches to a bottom  1126 , which is substantially planar. Each bottom  1126 , in turn, has two substantially parallel sides  1128 , which are substantially perpendicular to bottom  1126  and extend upwardly. 
     FIGS. 24-26, illustrate a third embodiment of the present invention in the form of bracket  324 . Bracket  324  is substantially identical to bracket  224  except for the presence of stiffening ribs  2122  in main portion  2100 , and the presence of a third hole  2125  through the center of main portion  2100 , to provide an alternative manner for attaching box  12  to bracket  324 , that is, by a bolt extending through hole  2125 . Thus, bracket  324  can provide stronger, stiffer support then bracket  224 , as needed. 
     Bracket  324  has a main portion  2100  and two extensions  2102 . Main portions  2100  has a top  2110 , which is substantially planar. Main portion  2100  also has coupling elements  2116  for connecting with junction box  12  or a fan or fixture bracket. Coupling elements are preferably threaded holes for receiving box mounting screws  118 , although they can be any device to capture the fastening device used to secure junction box  12  to bracket  24 . Extensions  2102  are located at each end  2114  of main portion  2100 . Each extension  2102  has in inclined narrow strip  2124  that attaches to a bottom  2126 , which is substantially planar. Each bottom  2126 , in turn, has two substantially parallel sides  2128 , which are substantially perpendicular to bottom  2126  and extend upwardly. 
     Again, while an advantageous embodiments have been chosen to illustrate the invention, it will be understood by those skilled in the art from this disclosure that various changes and modifications can be made therein without department from the scope of the invention as defined in the appended claims.

Technology Classification (CPC): 8