Abstract:
An electrical box assembly for mounting a security camera or an electrical fixture on a wall or ceiling. The electrical box assembly includes an electrical box with a sidewall and back wall defining an enclosure therein. A flange extends laterally from the rim of the sidewall. A plurality of rotatable flags, adjustable from the front of the electrical box assembly, are tightened to secure the assembly to the wallboard in a ceiling or wall. Wall preparation for installation of the electrical box assembly requires only a round hole in the wallboard, which can be easily provided by a hole-saw. Recessed areas in the sidewalls of the electrical box enable retracting of the flags to enable easy insertion of the sidewalls within the hole in the wallboard. An adapter plate enables the mounting of a security camera to the electrical box assembly.

Description:
FIELD OF THE INVENTION 
     This invention relates to the installation of electrical components and specifically to an electrical box for mounting a security cameras or electrical fixtures on a wall, ceiling, or similar surface. 
     BACKGROUND OF THE INVENTION 
     Security cameras and electrical fixtures are commonly installed on the interiors and exteriors of buildings. Security cameras are frequently installed to provide monitoring of property against intrusion, vandalism, or theft. Electrical fixtures, such as lighting fixtures, are also frequently installed. Electrical fixtures typically run on house current and therefore all electrical connections to the fixtures must be contained within a closed electrical box that is in compliance with all local electrical codes. Although most security cameras are powered by 24 volts, many jurisdictions now require that the electrical connections also be contained within a closed electrical box that meets the electrical code. 
     As security cameras and light fixtures are typically installed on ceilings or walls, it is desirable to recess the electrical connections within the walls of the building in order to occlude the view of the box that holds the electrical connections as much as possible. Conventional electrical boxes are typically not adaptable to accepting either a security camera or an electrical fixture, therefore requiring the installer to purchase an electrical box that is specifically adapted to either the security camera or to the electrical fixture. 
     What is needed therefore is an electrical box that can be used for installing either an electrical fixture or a security camera on a wall or ceiling. The electrical box should be capable of being easily adapted for the rapid installation of either an electrical fixture or a security camera on a wall or ceiling. Providing one electrical box that is capable of serving two functions reduces stocking requirements and reduces the amount of equipment that must be hauled to the job site by the installer. The mounting of the electrical box should require only the use of a standard hole-saw for preparation of the ceiling or wall. 
     SUMMARY OF THE INVENTION 
     The invention is an electrical box assembly for mounting a security camera or an electrical fixture on a wall or ceiling. The electrical box assembly includes an electrical box with a sidewall and back wall defining an enclosure therein. A flange extends laterally from the bottom end of the sidewall. A plurality of rotatable flags, adjustable from the front of the electrical box assembly, are tightened to secure the assembly to the wallboard in a ceiling or wall. Wall preparation for installation of the electrical box assembly requires only a round hole in the wallboard, which can be easily provided by a hole-saw. Recessed areas in the sidewalls of the electrical box enable retracting of the flags to enable easy insertion of the sidewalls within the hole in the wallboard. An adapter plate enables the mounting of a security camera to the electrical box assembly. 
     OBJECTS AND ADVANTAGES 
     Several advantages are achieved with the electrical box assembly of the present invention, including:
         (1) The electrical box assembly provides a mounting platform for both security cameras and electrical fixtures.   (2) The electrical box assembly provides a rapid means of installing security cameras and electrical fixtures on either walls or ceilings.   (3) Wall preparation time is greatly reduced as a standard hole-saw and a single hole are all that are required for installation of the electrical box.   (4) The electrical box assembly is capable of supporting up to a 50 pound load with the connection of a support wire to the electrical box.   (5) The electrical box assembly provides a secure enclosure for holding wiring connections, including 110 volt AC or 24 volt DC current.   (6) An adapter plate enables rapid mounting of a security camera to the electrical box assembly.       

     These and other objects and advantages of the present invention will be better understood by reading the following description along with reference to the drawings. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of the preferred embodiment of an electrical box assembly according to the present invention. 
         FIG. 2  is a top perspective view of the electrical box assembly of  FIG. 1 . 
         FIG. 3  is a top view of the electrical box assembly of  FIG. 1  with the rotatable flags rotated inward for installation. 
         FIG. 4  is a top view of the electrical box assembly of  FIG. 1  with the rotatable flags rotated outward to secure to a ceiling or wall. 
         FIG. 5  is an exploded perspective view of the electrical box assembly of the present invention in alignment with a security camera that it will support. 
         FIG. 6  is a bottom view of the electrical box assembly including the mounting bar for the adapter plate and the ground strap attached thereto. 
         FIG. 7  is a bottom view of the electrical box assembly with the adapter plate secured thereto. 
         FIG. 8  is a perspective view of the electrical box assembly secured to a ceiling with an attached adapter plate and a security camera in alignment to be secured to the electrical box. 
         FIG. 9  is a perspective view of the electrical box assembly of  FIG. 7  after the electrical box has been secured to the ceiling and a security camera secured to the electrical box assembly. 
         FIG. 10  is a side view of the electrical box assembly of the present invention. 
         FIG. 11  is a side view of the electrical box assembly with a security camera attached thereto. 
         FIG. 12  is a perspective view of the electrical box assembly and security camera of  FIG. 10 . 
         FIG. 13  is a perspective view of a mounting bar that can be used with the electrical box assembly of the present invention for mounting a security camera to the assembly. 
         FIG. 14  is a perspective view of a grounding strap that can be used with the electrical box assembly of the present invention. 
         FIG. 15  is a perspective view of an adapter plate that form a portion of the electrical box assembly for mounting a security camera thereto. 
     
    
    
     INDEX TO REFERENCE NUMERALS IN DRAWINGS 
     
       
         
               
               
             
           
               
                   
               
             
             
               
                 20 
                 electrical box assembly 
               
               
                 22 
                 electrical box 
               
               
                 24 
                 sidewall 
               
               
                 26 
                 back wall 
               
               
                 28 
                 electrical enclosure 
               
               
                 29 
                 sidewall end 
               
               
                 30 
                 mounting arrangement 
               
               
                 32 
                 mounting fastener 
               
               
                 34 
                 rotatable flag 
               
               
                 38 
                 flange 
               
               
                 40 
                 mounting boss 
               
               
                 42 
                 oversize bore in mounting boss 
               
               
                 44 
                 proximal end of flag 
               
               
                 46 
                 distal end of flag 
               
               
                 48 
                 bore in flag 
               
               
                 50 
                 foot 
               
               
                 52 
                 tab 
               
               
                 54 
                 flat face 
               
               
                 56 
                 recessed area 
               
               
                 58 
                 extended configuration 
               
               
                 60 
                 tie-off bar 
               
               
                 62 
                 knockout area 
               
               
                 64 
                 aperture in tie-off bar 
               
               
                 66 
                 open channel 
               
               
                 68 
                 rim 
               
               
                 70 
                 second channel 
               
               
                 72 
                 bore 
               
               
                 74 
                 retracted configuration 
               
               
                 76 
                 directional arrow 
               
               
                 78 
                 directional arrow 
               
               
                 80 
                 security camera 
               
               
                 81 
                 mounting bar 
               
               
                 82 
                 bar fastener 
               
               
                 83 
                 fastening arrangement 
               
               
                 84 
                 post 
               
               
                 86 
                 bore in post 
               
               
                 88 
                 opening of electrical box 
               
               
                 89 
                 base of mounting bar 
               
               
                 90 
                 prong on mounting bar 
               
               
                 92 
                 tab on mounting bar 
               
               
                 94 
                 aperture 
               
               
                 95 
                 strut 
               
               
                 96 
                 adapter plate 
               
               
                 97 
                 inside surface of prong 
               
               
                 98 
                 central aperture 
               
               
                 100 
                 flange on adapter plate 
               
               
                 102 
                 wiring aperture 
               
               
                 104 
                 ground strap 
               
               
                 106 
                 central bar 
               
               
                 108 
                 first end 
               
               
                 109 
                 second end 
               
               
                 110 
                 tab on ground strap 
               
               
                 111 
                 aperture 
               
               
                 112 
                 first aperture 
               
               
                 114 
                 second aperture 
               
               
                 116 
                 groove in electrical box 
               
               
                 117 
                 screw 
               
               
                 118 
                 aperture in adapter plate 
               
               
                 120 
                 directional arrow 
               
               
                 122 
                 ceiling 
               
               
                 124 
                 support wire 
               
               
                 D1 
                 diameter of sidewall of electrical box 
               
               
                 Θ1 
                 angle of rotation of flag to extend or retract 
               
               
                 Θ2 
                 angle of rotation for securing adapter plate 
               
               
                   
               
             
          
         
       
     
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIG. 1  there is shown a preferred embodiment of an electrical box assembly  20  according to the present invention, with portions of the assembly exploded away for clarification. The electrical box assembly  20  includes a one-piece electrical box  22  with a sidewall  24  and a back wall  26  defining an electrical enclosure  28  therein. Sidewall  24  includes an end  29 . A mounting arrangement  30 , shown exploded away from the electrical box  22 , includes mounting fasteners  32  and rotatable flags  34 . The sidewall  24  of the electrical box  22  includes a sidewall end  29  and a flange  38  extending laterally from the sidewall end  29 . 
     The one-piece electrical box  22  includes mounting bosses  40  that are integral with the sidewall  24 . The mounting bosses  40  include bores  42  therein which are oversize with respect to the mounting fasteners  32 , thus enabling the mounting fasteners  32  to turn freely in bores  42  after they are inserted there through. Each rotatable flag  34  is substantially rectangular shaped with a proximal end  44  at which it will be attached to the mounting fastener  32 , a distal end  46 , a bore  48  at the proximal end  44 , a foot  50  at the distal end  46 , and an outward extending tab  52  laterally from the rotatable flag  34  between the proximal end  44  and distal end  46 . A flat face  54  provided on the foot  50  will face the flange  38  of the electrical box  22 . 
     Referring to  FIG. 2 , the sidewall  24  of the electrical box assembly  20  includes a recessed area  56  corresponding to each of the rotatable flags  34  in the mounting arrangement  30 . The rotatable flags  34  may be rotated outward or inward by rotating the mounting fasteners  32  slightly more than ¼ turn. In  FIG. 2 , the rotatable flags  34  are depicted rotated outward to the extended configuration  58 . As shown in the top perspective view of  FIG. 2 , the electrical box  22  includes a tie-off bar  60  and one or more knockout areas  62  in the back wall  26 . The tie-off bar  60  includes an aperture  64  therein for later attachment of a support wire (not shown) for supporting the electrical box  22  when a heavy load is suspended there from. The mounting fasteners  32  extend through open channels  66  that are adjacent each recessed area  56 . When the mounting fasteners  32  are rotated clockwise as viewed from the open end of the electrical box  22 , the tabs  52  engage sidewall  24  and continued clockwise rotation of the mounting fasteners will draw the rotatable flags  34  toward the flange  38  of the electrical box  22 . Electrical box includes rim  68  at the outer periphery of the flange  38 . Second channels  70  are provided in the sidewall  24  of the electrical box  22  in alignment with bores  72  leading from posts (not shown) within the enclosure of the electrical box. 
     With reference to  FIG. 3 , the rotatable flags  34  of the electrical box assembly  20  can be rotated to a retracted configuration  74  wherein the rotatable flags  34  are rotated through angle Θ 1  in the direction of arrow  76  until each flag  34  contacts the sidewall  24  of the electrical box  22  within the recessed area  56 . With all three rotatable flags  34  rotated into the retracted configuration  74 , all portions of the flags  34  are within the outer periphery of the sidewall  24  and the electrical box  22  will thus be configured for insertion through a circular hole in wallboard (not shown) created by a hole-saw. 
       FIG. 4  depicts the rotatable flags  34  rotated into their extended configuration  58  in which the wherein the rotatable flags  34  are rotated through angle Θ 1  in the direction of arrow  78  until each tab  52  of flag  34  contacts the sidewall  24  of the electrical box  22 . With all three rotatable flags  34  rotated into the extended configuration  58 , the electrical box  22  will thus be configured for tightening of the mounting fasteners  32  in order to draw the flags  34  tightly against the wallboard (not shown) and thus clamp the electrical box  22  to the wall or ceiling. Preferably, angle Θ 1  is between 120 and 125 degrees. 
     With reference to  FIG. 5 , the electrical box assembly  20  of the present invention is depicted in alignment with a security camera  80  that it will support. The mounting fasteners  32  and rotatable flags  34  are shown exploded apart from the electrical box  22  for purposes of clarity. The electrical box assembly  20  is normally supplied with the mounting fasteners  32  extending through the mounting bosses  40  and the rotatable flags  34  attached to the ends of the mounting fasteners  32 . In order to support the security camera  80 , electrical box assembly  20  includes a mounting bar  81  that is secured with bar fasteners  82  to a fastening arrangement  83  for securing an electrical device (not shown) to the electrical box  22 . The mounting bar  81  is an elongated bar preferably constructed of metal. The fastening arrangement  83  for fastening an electrical device to the electrical box  22  includes posts  84  that are integral with the sidewall  25  of the electrical box  22 . Posts  84  including bores  86  therein are arranged approximately 180 degrees across the opening  88  of the electrical box  22 . As shown in  FIG. 13 , the mounting bar  81  includes an elongated base  89 , two prongs  90  extending from the base  89 , tabs  92  extending at a right angle from the prongs  90 , and apertures  94  for accommodating bar fasteners  82 . Two struts  95  extend from the mounting bar  81  to the inside surface  97  of the prongs  90  to stiffen and support them. 
     As shown in  FIG. 5 , the fastening arrangement  83  of the electrical box assembly  20  further includes an adapter plate  96 . The adapter plate  96  includes a central aperture  98  for interacting with the prongs  90  of the mounting bar  81 . As shown in  FIG. 15 , the adapter plate  96  includes flanges  100  extending into the central aperture  98 . A wiring aperture  102  is provided on the adapter plate  96  for accommodating the passage of electrical wiring (not shown) between the security camera and the electrical box. 
     Referring to  FIG. 5 , a ground strap  104  is shown in alignment with a post  84  in the electrical box  22 . The ground strap  104  is constructed of metal and is provided to enable the electrical box assembly  20  to meet code in certain jurisdictions where a ground wire must be connected within a non-metallic electrical box. As shown in  FIG. 14 , the ground strap  104  includes a central bar  106  with two bent over ends including a first  108  and second end  109 . A tab  110  and aperture  111  are provided on the first end  108  and a first aperture  112  and second aperture  114  in the second end  109 . As shown in  FIG. 5 , electrical box  22  includes a groove  116  therein against the sidewall end  29  at the opening  88  of the electrical box. Tab  110  of ground strap  104  clips into groove  116  in electrical box  22  to hold the ground strap  104  to the electrical box  22 . Connection of ground strap  104  to electrical box  22  could also be by screw  117  as shown. A ground wire (not shown) can be connected to the second end  109  of the ground strap  104  to provide electrical continuity to any electrical fixture or device that is secured to the electrical box  22 . The second aperture  114  provides a place for connecting the ground wire via screw (not shown) or similar fastener. 
     As shown in  FIG. 6 , the first step in preparing the electrical box assembly  20  for receipt of a security camera (not shown) is to secure mounting bar  81  to posts  84 . A portion of mounting bar  81  is broken away on the left side of the figure to show post  84 , which is connected to the electrical box  22  by bar fasteners  82 , one of which is depicted on the right side of the figure. 
     With reference to  FIG. 7 , after the mounting bar  81  is secured to the electrical box assembly  20 , apertures  118  are drilled in the adapter plate  96  by the installer to match the pattern of posts or similar connection devices (not shown) on the security camera to prepare the adapter plate  96  for connection to the security camera. The security camera is then secured to the adapter plate  96  with fasteners (not shown). Adapter plate  96  with attached security camera is then secured to the electrical box assembly  20  by placing the central aperture  98  over the tabs  92  and prongs  90  on the mounting bar  81  and turning the adapter plate  96  through angle Θ 2  or approximately one-quarter turn in the direction as shown by directional arrow  120 . 
     As shown in  FIG. 8 , after the electrical box  22  has been secured to a ceiling  122 , a broken away portion of which ceiling  122  is shown, and adapter plate  96  has been secured to the electrical box assembly  20 , the security camera  80  is aligned with the adapter plate  96  and secured thereto by inserting the security camera  80  over the prongs  90  and tabs  92  of the mounting bar  81  and turning approximately ¼ turn in the direction of arrow  120 . 
     With reference to  FIG. 9 , the security camera  80  is shown secured to the electrical box assembly  20  which in turn is secured to the ceiling  122 . Rotatable flags  34 , one of which is shown, have been fully tightened against the ceiling  122  to securely hold electrical box assembly  20  and attached security camera  80  to the ceiling  122 . Although the operating procedure for installing electrical box assembly  20  and security camera  80  depicted in  FIGS. 8 and 9  are described with respect to a ceiling, it should be understood that electrical box assembly  20  could also be used to install a security camera  80  or similar electrical device on a wall. 
     Referring to  FIG. 10 , the back wall  26  of the electrical box  22  includes tie-off bar  60  extending there from. Tie-off bar  60  includes an aperture  64  therein. As shown in  FIG. 11 , after electrical box assembly  20  has been secured to the wallboard of ceiling  122 , a support wire  124  can be attached to the tie-off bar  60  at aperture  64  to provide support for the security camera  80 . The support wire  124  is especially useful for supporting the weight of heavy electrical fixtures that may be attached to the electrical box assembly  20 . 
     With reference to the rear perspective view of the electrical box assembly  20  in  FIG. 12 , there is shown the mounting fasteners  32  and rotatable flags  34  in the extended configuration  58 . Rotatable flags  34  have been rotated to the extended configuration  58  at which tab  52  of rotatable flag  34  engages the sidewall  24  of the electrical box  22 . Knockout areas  62  can be removed to provide an aperture for leading electrical cable (not shown) into the electrical box  22 . As each mounting fastener  32  is tightened to draw the rotatable flag  34  toward flange  38 , open channel  66  acts as a guide for the rotatable flag  34  to ride along the sidewall  24  and proceed down the channel  66  until the flag  34  engages the wall or ceiling (not shown). 
     As shown in  FIG. 3 , the sidewall  24  of the electrical box  22  includes an outer diameter D 1 . Preferably, the shape of sidewall  24  is circular and diameter D 1  of sidewall  24  is slightly less than the size of a conventional hole-saw of a standard size. For example, for use with a 4.0-inch hole-saw, diameter D 1  of sidewall  24  is slightly less than 4.0 inches. With rotatable flags  34  rotated into recesses  56  of sidewall  24 , thus to their retracted configuration  74  as shown in  FIG. 3 , sidewall  24  of electrical box  22  can be easily inserted within a 4.0″-inch hole in a wall created by a conventional 4-inch hole-saw. For other sizes of electrical boxes  22  according to the present invention, the size of the sidewall  24  would be adjusted to a size slightly less than the size of the hole-saw that it is designed to be used in conjunction with. 
     Most preferably, the one-piece electrical box  22  of the present invention is molded in one piece of plastic and each of the rotatable flags  34  are molded in one piece of plastic. Preferably, the plastic is polycarbonate, polyvinyl chloride, acrylonitrile-butadiene styrene, or polyethylene. Preferably the mounting fasteners are #6×2-inch sheet metal screws. 
     Although the description above contains many specific descriptions, materials, and dimensions, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.