Patent Abstract:
An electrical junction box or a mounting assembly includes a box having a top wall and a side wall. The side wall extends downwardly away from the top wall and defines a cavity therein. A fixture support extends into the cavity and supports an electrical fixture. A threaded hole may be provided on the fixture support. Preferably, the fixture support has exposed portions which are sufficiently smooth for preventing wear to plastic-coated electrical wires which engage such exposed surfaces of the fixture support. Two or more fixture supports may be provided. The fixture support may enhance the use of conventional inwardly extending ears. An adhesive element, such as double-sided tape, may be provided on the box for rapid attachment thereof to a support surface.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of application Ser. No. 08/862,379, filed May 23, 1997, now U.S. Pat. No. 5,965,845, and this application is a continuation-in-part of application Ser. No. 08/905,141, filed Aug. 1, 1997, which claims the priority of application Ser. No. 60/023,060, filed Aug. 2, 1996, and which application Ser. No. 08/905,141 is a continuation-in-part of application Ser. No. 08/862,379, filed May 23, 1997, and which is a continuation-in-part of application Ser. No. 08/490,757, filed Jun. 15, 1995, now U.S. Pat. No. 5,677,512, which is a continuation-in-part of application Ser. No. 08/371,695, filed Jan. 12, 1995 now U.S. Pat. No. 5,854,443; and this application is a continuation-in-part of application Ser. No. 08/905,142, filed Aug. 1, 1997, which is a continuation-in-part of application Ser. No. 08/862,378, filed May 23, 1997, which claims priority of application Ser. No. 60/018,227, filed May 24, 1996; and this application is a continuation-in-part of application Ser. No. 08/905,077, filed Aug. 1, 1997, which is a continuation-in-part of application Ser. No. 08/862,378, filed May 23, 1997; and this application is a continuation-in-part of application Ser. No. 08/904,691, filed Aug. 1, 1997, which is a continuation-in-part of application Ser. No. 08/862,379, filed May 23, 1997; and this application is a continuation-in-part of application Ser. No. 08/862,380, filed May 23, 1997, which claims the priority of application Ser. No. 60/023,060, filed Aug. 2, 1996, and which application 08/862,380 claims the priority of application Ser. No. 60/018,227, filed May 24, 1996. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to electrical boxes and methods of producing the same. 
     BACKGROUND OF THE INVENTION 
     Consumers, updated National Electrical Codes (NEC), and Underwriter Laboratories (UL) requirements all require that electrical boxes be made stronger than n the prior art. 
     OBJECTS AND SUMMARY OF THE INVENTION 
     An object of the invention is to overcome the drawbacks of known electrical boxes. 
     Another object of the invention is to provide two (2) electrical boxes in one; e.g., an installer can use the inventive electrical box to install a first type of fixture requiring a first type of fastener, and the installer can use the box to install a second type of fixture requiring a second type of fastener, so that the installer always has the proper fastener. This object also fulfills the object of reducing the amount of inventory a retailer must carry. 
     A further object of the invention includes making electrical boxes which use the standard punched-out, stamped electrical boxes in a more intelligent fashion. 
     Yet another object of the invention is to provide a standard industry size electrical box with a fixture support for supporting a fixture, and that is located the proper distance from a second fixture support, and meets National Electrical Code (NEC) standards. 
     Another object of the invention is to fully exploit the strength of fixture support studs, the top wall, and the side walls of electrical boxes. 
     A further object of the invention is to provide a square junction box having fixture supports at four corners thereof. 
     A further object of the invention is to provide a junction box having four fixture supports, two fixture supports being a first type, and two fixture supports being of a second type. 
     A still further object of the invention is to provide a junction box suited for direct attachment to a mounting location, such as a ceiling joist, and for carrying the static and dynamic loading of a ceiling fan by itself. 
     Another object of the invention is to provide a junction box having a fixture support which is a rivet and/or a modified pull rivet. 
     Another object of the invention is to provide a junction box having a fixture support with strengthening members disposed thereon for securing the attachment of the fixture support to the junction box, as well as for enhancing the load-carrying capability of the box, such as for carrying electrical fixtures. 
     Another object of the invention is to achieve a strengthened electrical box with a fixture support that is contained within a standard so-called “4×4” box, while maintaining the near universal 3.5 inch (8.9 cm) spacing between the fixture supports so that the box is usable with standard light fixtures, ceiling fans, and the like, and so that the box can be located in a standard 4″×4″ hole in a gypsum board wall, for example. 
     It is likewise an object of the invention to provide metal inserts in and/or on the electrical boxes to enhance the carrying strength of the electrical boxes. 
     A further object of the invention is to provide studs in the electrical boxes that strengthen the electrical boxes. 
     Yet another object of the invention is to provide studs in the electrical boxes which cover the threads of standard screws so that no screw threads are present in the interior of such electrical boxes. 
     A still further object of the invention is to provide an electrical box having a fixture support with a sufficiently smooth exterior for preventing wear to the plastic coating of plastic-coated electrical wire. 
     It is yet another object of the invention to provide electrical boxes in which supports, such as studs, are added during the manufacturing process to eliminate problems in prior art electrical boxes, as well as to strengthen the inventive electrical boxes. 
     Another object of the invention is to provide a junction box having a fixture support, yet which requires no screwing of fasteners nor welding during assembly thereof. 
     Yet another object of the invention is to provide an electrical box having components which are easily fabricated, added to the electrical box, and assembled in the final form by the operation of pressing or riveting, yet which do not loosen when subjected to static and/or dynamic loading. 
     A still further object of the invention is to provide a junction box in which the fixture support for carrying static and dynamic loads automatically extends in the desired direction along the side walls of the junction box during assembly and/or in use thanks to the fixture support being configured for engaging the side wall and/or fixture support when the support is attached and located in its attached, final form ready for use. 
     A still further object of the invention is to provide a junction box capable of carrying static and/or dynamic loads that has an support and that is assembled with fewer parts and with fewer steps than known devices. 
     It is a yet further object that all the above be carried out with an electrical box which carries the load of supported static and dynamic fixtures better than known electrical boxes. 
     In summary, the present invention is directed to an electrical junction box or mounting assembly which includes an electrical junction box or mounting assembly including a box having a top wall and a side wall. The side wall extends downwardly away from the top wall and defines a cavity therein. A fixture support extends into the cavity and support an electrical fixture. A threaded hole may be provided on the fixture support. Preferably, the fixture support has exposed portions which are sufficiently smooth for preventing wear to plastic-coated electrical wire which engages such exposed surfaces of the fixture support. Two or more fixture supports may be provided. The fixture support may enhance the use of conventional inwardly extending ears. An adhesive element, such as double-sided tape, may be provided on the box for rapid attachment thereof to a support surface. 
     These objects and advantages as well as others will be readily apparent from a review of the following description and drawings. 
     The drawings show a variety of embodiments of the invention, as will be clear from reading the description below. 
     It is important to note that the use of relative terms such as “up” and “down”, and “left” and “right” is for convenience only and is not intended to be limiting. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a cross sectional view of a PRIOR ART electrical junction box having an inwardly extending ear E with a fixture attachment hole F provided therein, and the hole F is typically provided with support threads the supporting length of which are limited to the thickness of the metal ear E; 
     FIG. 2 is a perspective view of a preferred embodiment of an electrical junction box according to the invention having four supports; 
     FIG. 3 is a top plan view of FIG. 2; 
     FIG. 3A is a cross-sectional view of optional fluting; 
     FIG. 4 is a perspective view of a still further preferred embodiment of a junction box according to the invention that has four (4) fixture supports; 
     FIG. 5 is a further perspective view of the box of FIG. 4; 
     FIG. 6 is a perspective view, similar to FIG. 4, of another preferred embodiment of a junction box according to the invention; 
     FIG. 7 is a perspective view of the box of FIG. 6; 
     FIG. 8 is a perspective view of another embodiment of a support for use with the embodiment of FIGS. 6 and 7; 
     FIG. 9 is a perspective view, similar to FIG. 4, of another preferred embodiment of a junction box according to the invention; 
     FIG. 10 is a perspective view of the box of FIG. 9; 
     FIG. 9A is a perspective view, similar to FIG. 9, of another preferred embodiment of a junction box according to the invention; 
     FIG. 10A is a perspective view of the box of FIG. 9A; 
     FIG. 11 is a perspective view of another preferred embodiment of a junction box according to the invention; and 
     FIG. 12 is a exploded perspective view of yet another preferred embodiment of a junction box according to the invention. 
    
    
     DESCRIPTION OF THE PRIOR ART 
     FIG. 1 shows a PRIOR ART junction box including a side wall S, an upper wall U, and an ear E extending from a lower portion L thereof. 
     Upper wall U has one or more attachment holes A through which fasteners will be inserted for attaching PRIOR ART electrical box B to an overhead surface, such as to a ceiling joist or piece of plywood extending therebetween. 
     A lower, fixture or faceplate attachment hole F is typically provided in inwardly extending ear E. Frequently, faceplate hole F is provided with threads for mating with respective faceplate fasteners when securing an unillustrated faceplate thereto. Such faceplates are used to enclose electrical box B after the wiring inside the electrical box/junction box B has been completed. 
     A drawback of such PRIOR ART electrical boxes B is that they are typically made with stamped sheet metal extensions E; consequently, extensions E are relatively thin (i.e., in the order of about 1 millimeter or less). Such extension or ear E has a width of only a few millimeters,and only extends several millimeters inside box B. Thus, the surface area of ear E, when viewed from below after installation of upper wall U against a typical horizontal ceiling, is often substantially less than one centimeter squared (1 cm 2 ). In addition, the carrying strength of the typically threaded hole F is limited by the thickness of the metal from which ear E is made. Consequently, ear E may only carry relatively small vertical loads, when installed against the ceiling, as described above. 
     As a result, local codes frequently allow such PRIOR ART boxes B to be used only for supporting the weight of a faceplate, or of a relatively light static or dynamic load, such as a light fixture or fan weighing 35 lbs. or less. 
     Such electrical boxes B are unsuited for supporting large static loads, as well as for supporting large dynamic loads, such as ceiling fans which may weigh sixty (60 lbs.)/twenty-seven kilograms or more (27 kg). 
     Thus, there is a need for an electrical box which is suited for carrying relatively large static loads as well as dynamic loads. 
     That need is especially clear, given that many homeowners want to install heavier light fixtures and dynamic loads, such as ceiling fans, than had exhibited such preferences in the past. 
     Furthermore, even if the initial owner/builder of a house or commercial space provides PRIOR ART load-carrying junction boxes B suited for carrying the vertical force of a small light fixture, a subsequent owner/user will often replace the original light fixture with a heavier light fixture, or with a dynamic load; i.e. a ceiling fan. 
     Accordingly, there is a need for a load-carrying junction box which is suited for a wide range of static and dynamic loads and, thus, suited for original installation in new construction, given that some users fail to upgrade load-carrying junction boxes when adding heavier static and/or dynamic loads to the box. 
     The electrical box according to the invention has overcome these drawbacks described immediately above, and has achieved the objects of the invention detailed above. Such will be evident when reading the following detailed description of the invention. 
     DETAILED DESCRIPTION OF THE INVENTION 
     FIGS.  2  and  3   
     Turning to FIGS. 2 and 3, a first preferred embodiment of an electrical box and/or junction box  10  according to the invention will now be described in detail. 
     Junction box  10  includes a top wall  14 , and a side wall  18  extending downwardly therefrom and defining a cavity C therein. Side wall  18  includes a lower free edge  20 . 
     Preferably, one or more punchouts  24  are provided on top wall  14 , for example. 
     Additional holes or punchouts  36  for receiving portions of an electrical fixture, for example, and/or for receiving fasteners which secure junction box  10  to a ceiling or joist, for example, may likewise be provided. 
     A fastener  42 , such as a screw, bolt, or a rivetable head directly connected to support  40  may be provided. Such rivet-like fasteners  42  may be constructed so that, on installation, an upper region  46  of fastener  42  compresses sufficiently for “locking” fastener  42  to box  10  thanks to top wall  14  of box  10  being held between compressed upper region  46  and fastener head  48 . The need for such compression and the extent thereof will be determined by the materials involved, and whether an additional strengthening element is used, for example. 
     FIG. 2 illustrates a support  40  which may be provided for increasing the holding strength of junction box  10 . 
     Support  40  may be made with a height substantially equal to the distance between lower free edge  20  and the inner face of top wall  14  (i.e., the face facing cavity C). 
     Depending on the fixture to be installed, support  40  will be disposed completely within cavity C or will extend out past lower free edge  20 . This is true for all the preferred embodiments of the invention. 
     Preferably, a second pair of spaced apart further fixture supports  50  will be provided. 
     Further fixture supports  50  may be provided spaced apart from the paired fixture supports  40 ; or, fixture supports  50  and  40  may be disposed substantially adjacent each other. For many applications of box  10 , an important consideration is maintaining a standard offset between the center lines of threaded holes  54 , 54  and between threaded holes  44 , 44  so that box  10  may be used for supporting lights and ceiling fans having such standard spacing. Standard spacing nowadays when box  10  is in use is set at 3.5 inches center-to-center. 
     Good results have been achieved when threaded hole  54  of fixture support  50  has a thread size which differs from the thread size of threaded hole  44  of support  40 . For example, threaded hole  54  may be a 10-32 inch female thread for mating with a 10-32 male thread on fastener F, and threaded hole  44  may be provided with a 8-32 inch female thread for mating with counterpart male {fraction (8/32)} inch may threads on fastener L. In that manner, the pair of fixture support  50  would be used when the installer is mounting a ceiling fan with fasteners F, and the paired fixture supports  50  could be used when the installer is mounting a light fixture by using fastener L. In that manner, the object of providing two boxes in one so that the installer always has the correct electrical box on hand is achieved. 
     Junction box  10  may have metal walls and a cross-shaped or plus sign (“+”) strengthening element  80 , which likewise may be made of metal. It is contemplated that top wall  14  and side wall  18  may be made of plastic, and strengthening element  80  be made of metal or plastic, or vice versa. 
     Strengthening element  80  may be provided with holes  84  aligned with holes  24  so that supports  40  and  50  pass therethrough; likewise, strengthening element  80  may be provided with holes  86  aligned with holes  36  in top wall  14  so that a box fastener S may extend therethrough for securing box  10  to a support, such as a wall stud or the lower face of a ceiling joist. Strengthening element  80  may be a “+” sign shaped plate, for example. 
     Alternatively threads  44  may be 8-32 threads which are standard for receiving light fixture fasteners, and threads  54  may be 10-32 threads which are standard for receiving the mating 10-32 male threads of ceiling fan fasteners. 
     Accordingly, alternately, in use, the user would attach a ceiling fan to the paired supports  50  by use of a ceiling fan fastener F. In a like manner, the user would attach a light fixture to paired supports  40  by use of a pair of light fixture fasteners L. 
     It is contemplated that each of the fixture fasteners  40  and  50  have the same thread size or different thread sizes, depending on the expected use. 
     When two fixture supports  40  are attached to the left and right ones of holes  24 , placement of support  40  substantially adjacent side wall  18  yields the added benefit of achieving a standard center-to-center spacing between respective threads  54  of each of the two supported supports  40 , even when using “standard” box forming equipment for making a standard box size, as discussed in greater detail below. Such also has the benefit of allowing use of standard equipment for forming holes in a sheetrock ceiling for receiving box  10 , while maintaining the standard 3.5 inch fixture fastener offset. 
     It will be appreciated that there are advantages in restricting the tendency of support  40  to move within a vertical plane. Such restriction helps maintain the integrity of the initial connection between support  40  and junction box  10 ; e.g., the connection between both top wall  14  and support  40 , and between side wall  18  and support  40 . 
     Still further, restricting such tendency of support  40  to move/rotate within a vertical plane helps to ensure that support  40  (and threads  52 ) extend substantially parallel to side wall  18  of junction box  10  before and during use, for example. Needless to say, all those aspects of fine-tuning of the connection between support  40  and the remainder of junction box  10  are geared for achieving predictability of where the lower portion of threads  54  support  40  is. 
     Head  42  of support  40 , for example, likewise assists in locating support  40  relative to box  10  and in restricting movement relative thereto. Head  42  may be provided with a diameter of 0.375 inches (9.525 mm) when a body  46  has a diameter of 0.25 inches (6.35 mm). 
     Needless to say, the disclosed connections and configurations act to restrict all movements between supports  40  and/or  50  and the remainder of box  10 . The above discussion regarding restriction of movement within a “vertical” plane is merely an example. 
     By restricting movement of supports  40  and/or  50 , there is achieved the desired predictability of where the lower portion of female thread  44 ,  54  is located so that the desired spacing between a left hand one of support  40  and a right hand one of support  40  is achieved. Typically, the spacing between the commonly provided two (2) female threads  44  and  54  (i.e., left and right ones) attached to and extending from left and right ones of supports  40  and  50 , respectively, as shown in broken-away portion of FIG. 2 will be achieved. Known light fixtures, for example, are provided with respective left and right male fasteners, three and one half (3½) inches on center, which will be mated with such left and right female threads  44  and  54 , during final use of the illustrated junction boxes. 
     All the advantages described regarding the stabilizing of and the location of threads  44  and  54  and, hence, support  40  and  50 , relative to the remainder of junction box  10  hold true for all the other preferred embodiments of the invention. 
     FIG.  3 A 
     When increased resistance to inadvertent turning of support  40  about the longitudinal axis of fastener  42  is desired, support  40  may be provided with an outer surface or face  45  with or without fluting  47  configured for engaging with a portion of hole  24  for restricting rotation of support  40 . As shown in FIG. 3A, configured face  44  may be made as a rough or knurled surface, with fluting  47  thereon. Such may be made as disclosed in Applicant&#39;s co-pending application Ser. No. 08/862,379, filed May 23, 1997, which is incorporated herein by reference, as well as in Applicant&#39;s copending application Ser. No. 08/905,142, filed Aug. 1, 1997, which is incorporated herein by reference. 
     The non-configured exterior face of support  40  may be made as a rounded surface  46 , as shown. Good results have been achieved with individual flutes of fluting  47  being sufficiently long to extend outwardly of a rounded/relatively smooth surface of hole  24 . 
     In one embodiment, fifteen (15) to twenty (20) flutes were used on support or stud  40  having a nominal diameter of 0.25 inches (6.35 mm). There may be as few as one (1) to fourteen (14) flutes on fluting  47 , for example, depending on the flute length and the intended use of the standard 4″ box. 
     When using fixture supports, such as support  40  having fluting  47 , there is no need to compress support  40  along its longitudinal axis relative to head  42  and in the region of head  42 , as is done with conventional rivets having no fluting  47 . Rather, the inventive box may be assembled by inserting support  40  through hole  24 . When the flutes of fluting  47  engage the inner wall defining hole  24 , sufficient force will be applied on support  40  so that the outwardly extending fluting  47  engages with/cuts into the material of top wall  14  of box  10 , for example. In the case where strengthening element  80  is used, holes  84  of strengthening element  80  may be sized so that fluting  47  engages with the side walls of holes  84 , or not, depending on the intended use. 
     Good results have been achieved when a threaded hole  54  is provided extending at least partially through support  40 . Preferably, threaded hole  54  has threads selected to mate with those of fasteners of electrical fixtures such as lights and ceiling fans. Typically, threads  54  are provided at least a lower portion of support  40 . 
     Support  40  may be attached to box  14  by use of a powered tool driving (e.g., pressing or riveting) support  40  into hole  24 , such as described in relation to FIGS. 2 and 3 of Applicant&#39;s co-pending application Ser. No. 08/905,142 filed Aug. 1, 1997, which is incorporated herein by reference. 
     The threads of threaded hole  54  may extend substantially the entire length through support  40 , so that fasteners of various lengths for attaching a light fixture or ceiling fan, for example, may be attached to support  40  and, hence, to electrical box  10 , from below during use. 
     It is likewise contemplated that threads  54  will only be provided at the top portion of support  40 , at the bottom portion of support  40 , or at both top and bottom portions with an unthreaded region in between. 
     FIGS.  4  and  5   
     FIGS. 4 and 5 illustrate a further preferred embodiment of a junction box  100  according to the invention. 
     Junction box  100  includes top wall  14 , side wall  18 , and at least one ear  104  attached to a lower portion  108  of side wall  18 . Ear  104  may be attached anywhere along side wall  18 , or to top wall  14 , depending on the intended use. 
     Ear  104  includes an extension  102  which may have a hole  112  therein. Hole  112  may be threaded. Hole  112  may extend through ear  104 . 
     Box  100  may include an additional support  114  having an extension or support  116  for assisting in the securing of a support lug  118  having a hole  120  therein. Hole  120  may be threaded for ease in attaching conventional fixture fasteners F and L, for example. Support lug  118  may be provided with a lip  121  which assists in rigidifying the connection between top wall  14  and lower portion  108  of side wall  18  for enhancing the carrying capability of support  114 . 
     A cutout  123  in side wall  18  may be provided to accommodate at least a portion of lip  121  so that a lower face  125  of support lug  118  does not extend past lower free edge  20  of box  100 . In that manner, a face plate or fixture may be mounted flush with lower free edge  20 . 
     The features of support  114  may be further appreciated by considering FIG.  10  and the related text, for example, as well as the other embodiments, of co-pending application Ser. No. 08/862,380, filed May 23, 1997, and which is incorporated herein by reference. That previously filed FIG. 10 embodiment works as well as the present embodiment; however, box  100  provides the flexibility of securing ceiling fans to fixture support  114 , while having the option of attaching a light fixture to fixture supports  120 , for example. Thus, the installer has two types of boxes in one. For example, hole  112  may be provided with 8-32 threads for securing a light fixture with fastener L having mating male 8-32 threads; and, hole  120  may be provided with female 10-32 threads for mating with male 10-32 threads of fastener F when the installer wants to install a ceiling fan or chandelier, for example. 
     Junction box  100  may include a piece of double-sided tape  122  on top wall  14  thereof. Double-sided tape  122  may be provided with an adhesive portion  124  and a protective strip or layer  128  on the outer face thereof, i.e., on the face of adhesive portion  124  of double-sided tape  122  that has not been adhered to junction box  100 . Conventional double-sided tape  122  may be used. 
     Alternative means for adhering junction box  100  to a surface may be used, such as spray-on adhesive, a piece of putty and other adhering means. Each of those adhering means is as described in my earlier U.S. patent application Ser. No. 08/490,757, filed Jun. 15, 1995, now U.S. Pat. No. 5,677,512, which is a continuation-inpart of 08/371,695, filed Jan. 12, 1995, now U.S. Pat. No. 5,854,443, each of which is incorporated herein by reference, and may be utilized in conjunction with or instead of the double-sided tape  122 . 
     One of the many advantages of junction box  100  is that the user may remove protective layer  128 , and then adhere an outer face of adhesive portion  124  of double-sided tape  122  to the surface to which junction box  100  is to be attached. Double-sided tape is selected and sized so that sufficient holding power for temporarily adhering or affixing junction box  100  to the surface is achieved, while the user has both hands free for permanently attaching junction box  100  in the desired location by hammering nails (or shooting screws) through one or more holes  36 . 
     Preferably, the adhesive is sufficiently strong to adhere box  100  to a horizontal surface located above the user&#39;s head, and for a sufficiently long period of time so that the user may release box  100  after adhering box  100  to a ceiling or wall, locate a fastener (e.g., nail or screw), and still have enough adhering time left to use both of his or her hands to install the fastener by hammering, screwing, or the like. 
     The thickness of double-sided tape  122  may be coordinated with the thickness (i.e., height) of any unillustrated outwardly extending top wall protrusions  14 , as necessary. 
     In addition, it is contemplated that the thickness of tape  122  will be varied depending on the characteristics of the surface of the material to which junction box  100  is to be adhered. 
     FIGS.  6 - 8   
     FIGS. 6-8 illustrate another preferred embodiment of a junction box  150  according to the invention. 
     Junction box  150  includes some features from the embodiments described above. For example, junction box may  150  include extension  104  having a threaded hole therein for supporting a light fixture, for example. Extension  104  typically extends from lower portion  108  of side wall  18 . Hole  36  may be provided in top wall  14  of box  150 , likewise as described above. 
     A fixture support  160  may be supplied in addition to paired extensions  104 . 
     Support  160  may include from one to three side walls  162 , depending on the intended use. Typically, again depending on the intended use, a bottom wall  163  having a threaded hole  164  therethrough and/or a top wall  165  having a threaded hole  168  therethrough may be provided. As in the above embodiments, the thread size will typically be dictated by the type of threads used by the expected fixture to be supported. It is contemplated that, as in the other embodiments, hole  112  may have 8-32 threads which are typically used for attaching corresponding male fasteners having 8-32 threads, such as are generally provided with contemporary light fixtures. One or both of threaded holes  164  and  165  may be provided with 10-32 threads for mating with counterpart 10-32 male threads on a fastener T that is used to support a ceiling fan or a chandelier, for example. Other types of threads are contemplated for use with thread sizes other than 8-32 and 10-32. Still further, it is contemplated, as in all the other embodiments, that one or more of holes  112 ,  164  and  168  may be free of threads, and self-tapping fasteners may be used for securing fixtures to such unthreaded holes. 
     Conveniently, in the case where a bottom wall  163  is provided bottom wall  163  may be provided in the same plane as the face of lower portion  108  of side wall  18  and/or the lower face of extension  104  so that a cover plate may be attached (flush) thereto as desired. In addition, it is contemplated that bottom wall  163  will be recessed and disposed completely within cavity C or bottom wall  163  will extend outwardly of cavity C (i.e., will extend past lower free edge  20  of box  150  (depending on the intended use). 
     As will be appreciated, in the case where at least two opposed side walls  162  are provided, in addition to lower wall  163  and upper wall  165 , a strong supporting structure will be realized given the open, box-like structure of the illustrated support  160 . It will be appreciated that a high strength to weight ratio for support  160  has been achieved with such. 
     It is further contemplated that an extension or lug  170  may be provided on support  160 . Support  160  and lug  170  may conveniently initially be made as a separate component which is attached to the remainder of box  150  prior to use. In such a case, lug  170  may be attached to side wall  18  by the use of a pressure joint  174 . Pressure joint  174  is shown as a plus sign (“+”). Pressure joint  174  may be formed during assembly of box  150  by the use of conventional stamping/pressing equipment. 
     During assembly of box  150 , box  150  may be provided with a slot through which lug  170  extends, for example, so that lug  170  is disposed on the outside of side wall  18  while the remainder of support  160  (i.e., side walls  162 , and top and bottom walls  163  remain on the interior of box  150 . Optionally, lug  170  may be provided with an optional inner layer or wall  175  which is disposed on the inside of side wall  18  and an outer layer or wall  177  disposed on the outer face of side wall  18 . After lug  170  is properly positioned, lug  170  and, hence, support  160  is secured relative to the remainder of box  150  (i.e., to side wall  18 ) by a stamping process, such as at pressure joint  174 . 
     In use, junction box  150  may be attached to a support surface in a manner analogous to the use of the above-described junction boxes. 
     A pair of heavy-duty fixture fasteners T is shown in FIG. 7 to emphasize that support  160  can be used to carry especially heavy loads, such as chandeliers over 60 lbs. and ceiling fans over 35 lbs. 
     FIGS.  9 ,  9 A,  10  and  10 A 
     FIGS. 9 and 10 illustrate yet another preferred embodiment of a junction box  180  according to the invention. 
     Box  180  is preferably provided with at least one pair of supports  160 , such as described above in connection with the embodiment of FIGS. 6-8. 
     Alternatively, as shown in FIG. 9A, junction box  200  may be provided with opposed pairs of supports  160 . In this case, a second pair of supports  160  is provided in addition to the illustrated pair of supports  160  of the embodiment of FIG.  9  and at a location similar to the location of the paired extensions  104  of FIGS. 6 and 7, for example. 
     The construction, operation and use of junction boxes  180  and  200  is analogous to that described above in connection with the previous embodiments. 
     For example, one pair of opposed supports  160  in the embodiment of FIGS. 9A and 10A may be provided with 8-32 female fasteners, while the other pair of supports  160  may be provided with 10-32 female fasteners for mating with the fasteners L and F and T, as desired, for example. 
     FIG.  11   
     FIG. 11 illustrates another preferred embodiment of a junction box  300  according to the invention. 
     Junction box  300  includes a side wall a  318  and a lower free-edge  320 . An upper edge  322  is likewise provided. 
     Typically, cavity C will be defined by an inner face  324  of side wall  318  and the inner face of a top wall which encloses the upper regions of box  300 . It is contemplated that box  300  may alternatively have an open upper end similar to the open lower end defined by free edge  320 . 
     Box  300  may be made of plastic, for example. 
     It is contemplated that at least one pair of opposed supports  340  be provided and that each support  340  will have a hole  344  defined therein. As in the other preferred embodiments, hole  344  may have internal threads, or not, depending on the intended use. When hole  344  is free of internal threads, self-tapping fasteners may be used for securing fixtures to box  300 , as in the other embodiments. Alternately, when holes  344  have no threads, and box  300  is opened ended, sufficiently long fasteners may be used so that the fasteners extend through the top of box  300  and are secured to box  300  by the use of nuts, for example, in the case where fasteners are screws or bolts. 
     As shown, it is likewise contemplated that a further pair of fixture supports  350  be provided, conveniently spaced apart from supports  340 . Typically, supports  350  will have holes  354  which differ in size from hole  344  of fasteners  340 , as in the other embodiments, so that different types of fasteners may be attached to hole  354 . As with support  340 , hole  354  may be provided with or without threads depending on whether or not the use of threaded, unthreaded, or self-tapping threaded fasteners is contemplated. Any variety of holes and thread sizes may be used. For use with current light, fans, and chandeliers, holes  344 , for example, will be provided with 8-32 internal threads, and holes  354  will be provided with 10-32 internal threads for use with light fixtures and ceiling fans/chandeliers, respectively. 
     The embodiment of FIG. 11 is shown with supports  350  illustrated as inwardly extending extensions, typically molded or extruded at the same time that side wall  318  is manufactured. In the case were supports  340  and  350  are provided as inwardly extending extensions, as shown, the volume of cavity C is relatively large, as will be appreciated. It is contemplated that supports  340  and  350  be provided as in a variety of shapes, or that side wall  318  will be sufficiently thickened around some or all of its entire perimeter so that hole  344  and  354  may be formed in side wall  318  without the need for inwardly extending extensions, as illustrated. 
     FIG.  12   
     Turning to FIG. 12 another preferred embodiment of an electrical box  400  according to the invention is illustrated. 
     Electrical box  400  is shown in an exploded view, and includes a housing  404  having an upper wall  414  with a hole  416  therethrough, and a downwardly extending side wall  418 . Upper wall  414  and side wall  418  define cavity C as in the other preferred embodiments. 
     A hole  416  is provided in top wall  414  so that a fastener can be inserted therethrough in order to secure electrical box  400  to a support, such as a joist. 
     A lower free edge  420  is provided on housing  404 . A recess or inset portion  424  is provided in side wall  418 , and a recess or inset portion  428  is provided in top wall  414 . 
     Conveniently, housing  404  may be made of plastic. 
     A support structure  430 , which may be mad e of metal, is sized and configured for mating with housing  404  as will be readily appreciated. Support structure  430  includes a top support element or plate  432  and at least one side support element or plate  434 . 
     Conveniently a hole  436  may be provided in top support element  432  that aligns with hole  416  of housing  404  when electrical box  400  is assembled for use. 
     At least a first pair of spaced apart fixture supports  440  is provided. Fixture support  440  includes side support element  434  and an outwardly extending support element or plate  432  which may be provided at a lower end thereof, as illustrated. 
     Support  440  further includes a hole  444  which may be threaded, as illustrated, that is provided in an extension  446  of support  440 . Conveniently, extension  446  may be provided with a head  448  by which extension  446  may be inserted through a hole in support  442  and secured by head  448 . It is contemplated that extension  446  have fluting thereon as in the above-described embodiments, and which fluting engages with the inner wall of the hole extending through support  442 . It is further contemplated that extension  446  be attached, such as by riveting, for example. 
     A further support  450  may be provided. Support  450  may likewise have a corresponding hole  454  with or without threads therein for receiving mating fasteners. As in the other preferred embodiments of the invention, it is contemplated that, in the case where holes  444  and  454  are threaded holes, hole  454  has 8-32 female threads and hole  454  has 10-32 female threads, for example, for mating with conventional light fixture fasteners L and chandelier/ceiling fan fastener F and T. 
     Support structure  430  may be integrally attached to housing  404  during the manufacturing process, or support structure  430  may be sufficiently resilient so that it may be snap-fit over housing  404  and aligned so that upper support  432  is disposed in the recess  428  and side support  430  is disposed in recess  424 , as will be readily appreciated. 
     It is further contemplated that support plates may be  442  provided at various locations spaced from upper support  432 , depending on the intended use. The illustrated disposition of support  442  at the lower end of support  430  is shown by way of example. The relative lengths of extensions  446  may be varied so that extension  446  are completely disposed in cavity C or extend outwardly thereof, depending on the intended use. 
     VARIATIONS 
     It is contemplated that in all the embodiments of the invention, the fixture supports and the related strengthening components, for example, may all be disposed on the interior of or the exterior of cavity C. 
     It has been found that for intended uses where relatively large static and dynamic forces are expected, fewer knurlings/flutes each extending outwardly of support  40  generally resist such forces better than more knurlings having a shorter length extending outwardly of the remainder of stud  40  for similar applications. 
     In addition to or instead of the supports and/or studs used in the various embodiments, it is expected that locking coupling nuts will be used to attach the fixture supports to the junction box, as well as any other means of fastening supports to the junction box in a sufficiently secure manner so as to achieve the objects of the invention. 
     It will be appreciated that these are merely examples of solutions to the problems set forth in my accompanying drawings and description, and, taken in its entirety, it will be appreciated that all the above objects of the invention, as well as many others, have been fulfilled. 
     It will likewise be appreciated that all the components described in the foregoing can be made of a variety of materials, such as steel, zinc, non-metallic materials, nylon, and other plastics, as the producer and user demand. 
     While this invention has been described as having a preferred design, it is understood that it is capable of further modification, uses and/or adaptations following in general the principle of the invention and including such departures from the present disclosures as come within known or customary practice in the art to which the invention pertains, and as may be applied to the essential features set forth, and fall within the scope of the invention or the limits of the appended claims.

Technology Classification (CPC): 4