Abstract:
A prepackaged fan and fixture mounting assembly for securing an electrical fixture, such as a ceiling fan, light fixture, or similar device to an overhead joist or other suitable structure. The mounting assembly includes an electrical box having a closed top, a sidewall, and an open bottom that define an electrical wiring enclosure. Provided within the electrical box are integral holsters for temporary storage of device fasteners. A bracket is provided attached to a recessed area in the sidewall for securing the mounting assembly to an appropriate surface. An electrical fan or fixture is installed to the electrical box by removing the device fasteners from their respective holsters and securing them through the mounting ring of the electrical fixture and into the mounting assembly.

Description:
This application is a Continuation-In-Part of U.S. patent application Ser. No. 10/816,518 entitled “Prepackaged Mounting Assembly”, filed Apr. 1, 2004 now U.S. Pat. No. 6,956,170, which is a Continuation-In-Part of U.S. patent application Ser. No. 10/790,973 entitled “Prepackaged Mounting Assembly”, filed Mar. 2, 2004 now U.S. Pat. No. 6,794,573, which is a Continuation-In-Part of U.S. patent application Ser. No. 10/723,122 entitled “Fan Rated Junction Box Assembly”, filed Nov. 26, 2003 now U.S. Pat. No. 6,777,615, which is a Continuation-In-Part of U.S. patent application Ser. No. 10/464,334 entitled Prepackaged Mounting Assembly and Bracket Combination, filed Jun. 18, 2003 now U.S. Pat. No. 6,734,356, which is a Continuation-In-Part of 10/361,292 entitled “Prepackaged Mounting Assembly with Holstered Screws”, filed Feb. 10, 2003 now U.S. Pat. No. 6,632,998, which is a Continuation-In-Part of U.S. patent application Ser. No. 10/287,088 entitled “Prepackaged Mounting Assembly”, filed Nov. 4, 2002 now U.S. Pat. No. 6,646,201, which is a Continuation-In-Part of U.S. patent application Ser. No. 10/012,584 entitled “Prepackaged Mounting Assembly”, filed Nov. 7, 2001, now U.S. Pat. No. 6,509,524, and is a Continuation-In-Part of U.S. patent application Ser. No. 10/017,571 entitled “Electrical Fixture Mounting Box and Mounting Assembly”, filed Oct. 22, 2001, now U.S. Pat. No. 6,677,523, which is a Continuation-In-Part of U.S. patent application Ser. No. 09/784,981 entitled “Electrical Fixture Mounting Box and Mounting Assembly”, filed Feb. 16, 2001, now U.S. Pat. No. 6,355,883, and is a Continuation-In-Part of U.S. patent application Ser. No. 09/373,431 entitled “Electrical Fixture Mounting Box”, filed Aug. 13, 1999, now U.S. Pat. No. 6,191,362, of which all of the above are incorporated by reference herein in their entireties. 

   FIELD OF THE INVENTION 
   The present invention relates to devices and methods for mounting ceiling fans, lights, and other large and heavy electrical fixtures to ceilings. More particularly, the present invention describes a fan and fixture mounting assembly for providing easy attachment of an electrical fixture to an overhead joist or similar building structure. The fan and fixture assembly comprises an electrical box and a bracket. Fasteners are held in temporary storage locations in the electrical box. The electrical box and bracket are secured to a suitable structural surface. The fasteners are removed from the temporary storage locations and moved to their permanent locations to secure a fan or an electrical fixture to the electrical box. The bracket includes several bends and integral brace members to provide superior stiffness and thereby enable it to support heavy suspended loads. 
   BACKGROUND OF THE INVENTION 
   The present invention expands upon the concept of the prepackaged mounting assembly that is disclosed in and shares inventorship with U.S. Pat. Nos. 6,191,362, 6,355,883, 6,509,524, 6,632,998, 6,646,201, 6,677,523, 6,734,356, 6,777,615, and 6,794,573, all of which are incorporated herein by reference. 
   The prepackaged mounting assemblies disclosed in these patents provide all the hardware needed for attaching a mounting assembly to an overhead beam, including all required fasteners to complete the installation, without the need for an outer wrap or separate packaging to hold the separate components. 
   In particular, U.S. Pat. No. 6,734,356 provided a prepackaged mounting assembly for securing an electrical fixture, such as a ceiling fan, light fixture, or similar device to an overhead joist or other suitable structure. The mounting assembly included an electrical box having a closed top, a sidewall, and an open bottom that defined an electrical wiring enclosure. Provided within the junction box were integral holsters for temporary storage of threaded fasteners. A bracket was provided attached to the closed top for securing the junction box to a surface. An electrical fan or fixture is then installed to the junction box by removing the threaded fasteners from their respective holsters and securing them through the top of the electrical fixture and into the bracket. 
   Although U.S. Pat. No. 6,734,356 provided an assembly for securing an electrical fan or fixture to an overhead surface, it has been found that a more secure fan and fixture mounting assembly can be achieved by increasing the stiffness of the bracket and increasing the amount of contact surfaces between the bracket and the electrical box. Accordingly, the present invention improves upon the prepackaged mounting assembly by making it more capable of supporting heavy loads. 
   OBJECTS AND ADVANTAGES 
   The mounting assembly of the present invention will therefore provide a mounting assembly having all the required hardware for securing an electrical fixture to the side of an overhead support. 
   An advantage of the present invention is that all required mounting fasteners are included with the mounting assembly. 
   A further advantage is that the mounting assembly provides a means of holding the fasteners very securely until needed at the job site, so that there will be no loss or displacement of fasteners during storage or shipment. 
   An additional advantage is that the fasteners are held in the mounting assembly in a manner that the ends of the fasteners are protected during storage and shipment. 
   The present invention therefore provides a mounting assembly that does not require separate packaging enclosing it or enclosing fasteners provided separately with the assembly. 
   The present invention will furthermore provide a mounting assembly including an electrical box and bracket arrangement having improved stiffness and load bearing capacity over prior art fan and fixture mounting assemblies. 
   These, and other advantages will be apparent to a person skilled in the art by reading the attached description along with reference to the attached drawings. 
   SUMMARY OF THE INVENTION 
   According to the present invention, there is provided a prepackaged fan and fixture mounting assembly for securing an electrical fixture, such as a ceiling fan, light fixture, or similar device to an overhead joist or other suitable structure. The mounting assembly includes an electrical box having a closed top, a sidewall, and an open bottom that define an electrical wiring enclosure. Provided within the electrical box are integral holsters for temporary storage of device fasteners. A bracket is provided attached to a recessed area in the sidewall for securing the mounting assembly to an appropriate surface. An electrical fan or fixture is then installed to the electrical box by removing the device fasteners from their respective holsters and securing them through the mounting ring of the electrical fixture and into the mounting assembly. 

   
     DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a preferred embodiment of a fan and fixture mounting assembly according to the present invention. 
       FIG. 2  is a perspective view of an electrical box portion of the fan and fixture mounting assembly of  FIG. 1 . 
       FIG. 3  is a bottom view of the electrical box of  FIG. 2 . 
       FIG. 4  is a side view of the electrical box taken along line  4 — 4  of  FIG. 3 . 
       FIG. 5  is a side view of the electrical box taken along line  5 — 5  of  FIG. 3 . 
       FIG. 6  is a top view of the bracket portion of the fan and fixture mounting assembly of  FIG. 1 . 
       FIG. 7  is side a view of the bracket taken along line  7 — 7  of  FIG. 6 . 
       FIG. 8  is an end view of the bracket of  FIG. 6 . 
       FIG. 8A  is a side view of the fan and fixture mounting assembly of  FIG. 1 . 
       FIG. 9  is a plan view of a blank used to form the bracket portion of the fan and fixture mounting assembly of the present invention. 
       FIG. 10  is a view of the bottom of the fan and fixture mounting assembly and an overhead joist it will be mounted to. 
   

   TABLE OF NOMENCLATURE 
   The following is a listing of part numbers used in the drawings along with a brief description: 
   
     
       
             
             
           
         
             
                 
             
             
               Part 
                 
             
             
               Number 
               Description 
             
             
                 
             
           
           
             
                20 
               fan and fixture mounting assembly 
             
             
                22 
               electrical box 
             
             
                24 
               bracket 
             
             
                26 
               sidewall 
             
             
                27 
               closed top 
             
             
                28 
               recessed area 
             
             
                30a 
               first surface 
             
             
                30b 
               second surface 
             
             
                30c 
               third surface 
             
             
                32a 
               first portion 
             
             
                32b 
               second portion 
             
             
                32c 
               third portion 
             
             
                34 
               outer surface 
             
             
                36 
               inner surface 
             
             
                38 
               first juncture 
             
             
                40 
               second juncture 
             
             
                42 
               first end of second portion 
             
             
                44 
               second end of second portion 
             
             
                46 
               brace member 
             
             
                48 
               outer surface of brace member 
             
             
                50 
               blank 
             
             
                52 
               bend line between first and second portion 
             
             
                54 
               bend line between second and third portion 
             
             
                56 
               bend line for brace member 
             
             
                58 
               forward edge of brace member 
             
             
                60 
               tab 
             
             
                62 
               opening 
             
             
                64 
               crimped area 
             
             
                66 
               opening 
             
             
                68 
               first depression 
             
             
                70 
               second depression 
             
             
                72 
               box mounting fastener 
             
             
                74 
               aperture 
             
             
                76 
               fastener 
             
             
                78 
               end portion of third portion of bracket 
             
             
                80 
               aperture 
             
             
                82 
               inner wall 
             
             
                84 
               inner cavity 
             
             
                86 
               bore or holster 
             
             
                88 
               device fastener 
             
             
                90 
               integral extension 
             
             
                92 
               open bore in integral extension 
             
             
                93 
               joist 
             
             
                94 
               threaded bore in second portion of bracket 
             
             
                96 
               permanent receptacle for device fastener 
             
             
                98 
               opening in second surface of electrical box 
             
             
               100 
               opening in second portion of bracket 
             
             
               102 
               snap engagement fitting 
             
             
               104 
               lower edge of sidewall 
             
             
               θ 1   
               angle between the first and second portions of the bracket 
             
             
               θ 2   
               angle between the second and third portions of the bracket 
             
             
               θ 3   
               angle of brace member from the portions of the bracket 
             
             
                 
             
           
        
       
     
   
   DETAILED DESCRIPTION 
   With reference to  FIG. 1 , the preferred embodiment of the fan and fixture mounting assembly  20  is used to secure an electrical fixture (not shown), such as a ceiling fan or a light, to an overhead joist, rafter, wall, or other structural surface. The mounting assembly  20  includes an electrical box  22  and a bracket  24 . 
   As shown in  FIGS. 4 and 5 , the electrical box  22  includes a sidewall  26 , a closed top  27 , a recessed area  28  in the sidewall  26  and a plurality of surfaces  30   a ,  30   b , and  30   c  thereon. 
   Referring to  FIG. 1 , the bracket  24  of the fan and fixture mounting assembly  20  includes portions  32   a ,  32   b , and  32   c  flush with several of the surfaces  30   a ,  30   b , and  30   c  in the recessed area  28  of the sidewall  26 . The bracket  24  is secured to at least one of the surfaces  30   b  of the electrical box  22 . 
   Referring to  FIG. 4 , the plurality of surfaces of the recessed area includes a first surface  30   a , a second surface  30   b , and a third surface  30   c.    
   With reference to  FIG. 8 , the bracket  24  includes a first portion  32   a , a second portion  32   b , and a third portion  32   c . Each of the three bracket portions  32   a ,  32   b , and  32   c  include an outer surface  34  and an inner surface  36 . The bracket  24  includes a first juncture  38  between the first portion  32   a  and the second portion  32   b  and a second juncture  40  between the second portion  32   b  and the third portion  32   c . The first juncture  38  includes a 90 degree angle θ 1  between the outer surface of the first portion  32   a  and the outer surface of the second portion  32   b . The second juncture  40  includes a 270 degree angle θ 2  between the outer surface of the second portion  32   b  and the outer surface of the third portion  32   c.    
   When the bracket  24  is secured to the electrical box  22 , as shown in  FIG. 8A , the bracket  24  includes portions flush with at least three of the surfaces  30   a ,  30   b , and  30   c  of the recessed area  28  of the electrical box  22 . As shown in  FIG. 8A , first portion  32   a  of the bracket  24  is flush with first surface  30   a  of the electrical box  22 , second portion  32   b  of the bracket  24  is flush with second surface  30   b , and third portion  32   c  of the bracket  24  is flush with third surface  30   c.    
   Referring to  FIG. 6 , the second portion  32   b  of the bracket  24  includes two ends  42  and  44 . A brace member  46  is integral with and extends from the ends  42 ,  44  of the second portion  32   b  of the bracket  24 . The brace members  46  have outer surfaces thereon  48 . The brace members  46  are at an angle θ 3  of 270 degrees from the outer surface  34  of the second portion  32   b  to the outer surface  48  of the brace member  46 . 
   The bracket  24  of  FIGS. 6–8  is typically formed from a flat blank  50  of metal as depicted in  FIG. 9 . The three major portions  32   a ,  32   b , and  32   c  of the bracket  24  are shown on the blank  50  prior to it being formed into its eventual shape. Bend lines  52 ,  54 , and  56  are shown in dotted lines in the figure, with bend line  52  between the first  32   a  and second  32   b  portions of the blank  50  and bend line  54  between the second  32   b  and third  32   c  portions of the blank  50 . The brace members  46  will be formed by bending along bend line  56 . The brace members  46  include a forward edge  58  and a tab  60  extending from the forward edge  58 . Openings  62  are included in the third portion  32   c  of the blank  50 . 
   To form the bracket from the blank  50  shown in  FIG. 9 , with the second portion  32   b  remaining in place, the first portion  32   a  is bent upward 90 degrees, the brace members  46  are bent downward 90 degrees, and the third portion  32   c  is bent downward 90 degrees. When the blank  50  is formed into the bracket, the forward edges  58  of the brace members  46  contact the third portion  32   c , as shown in  FIG. 7 , and the tabs  60  extend through the openings  62  in the third portion  32   c.    
   As shown in  FIG. 9 , the second juncture  40  includes one or more crimped areas  64  therein. The crimped areas  64  increase the stiffness of the bracket. 
   Referring to  FIG. 10 , the bracket  24  further includes openings  66  in the second portion  32   b  and two depressions  68  and  70  surrounding the openings  66 . One depression  68  is formed toward one side of the planar second portion  32   b  and the second depression  70  is formed toward the opposite side of the planar second portion  32   b . Box mounting fasteners  72 , shown exploded from the bracket  24  in  FIG. 10 , when inserted therein, are held frictionally within the openings  66  as shown in  FIG. 1 . The first portion  32   a  of the bracket  24  further includes apertures  74  therein which help in guiding the box mounting fasteners  72  through the bracket  24 . 
   As shown in  FIG. 1 , the bracket  24  is secured to the electrical box  22  by a fastener  76  secured through the second surface  30   b  of the electrical box  22  and into the bracket  24 . 
   With reference to  FIG. 7 , the third portion  32   c  of the bracket  24  includes end portions  78  extending outwards of the openings  62 . The end portions  78  include apertures  80  therein, with the apertures  80  extending substantially beyond the brace members  46  of the second portion  32   b  of the bracket  24 . The apertures  80  offer an alternative location for use in securing the fan and fixture mounting assembly to a surface, as a fastener (not shown) can be inserted therethrough to secure the mounting assembly to the surface. 
   Referring to  FIG. 3 , the sidewall  26  of the electrical box  22  includes inner walls  82  and an electrical wiring enclosure or inner cavity  84  therein. The inner walls  82  include bores or holsters  86  therein integral with the inner wall  82  of the electrical box. The fan and fixture mounting assembly  20  includes device fasteners  88  temporarily secured within the holsters  86 . 
   The sidewall  26  further includes a pair of integral extensions  90  from the inner wall  82  with each of the integral extensions preferably 180 degrees apart on the sidewall  26 . An open bore  92  is provided within each of the integral extensions  90 . 
   As shown in  FIG. 6 , threaded bores  94  are provided in the second portion  32   b  of the bracket  24 . 
   Referring to  FIG. 10 , the fan and fixture mounting assembly  20  is shown aligned with an overhead joist  93  to which it will be secured by box mounting fasteners  72 . The threaded bores  94  in the second portion  32   b  of the bracket  24  are in axial alignment with the open bores  92  of the extensions  90  thereby forming permanent receptacles  96  (see  FIG. 10 ) for the device fasteners  88 . The device fasteners  88 , when secured in the permanent receptacles  96 , are completely clear of engagement with the integral extensions  90 . Since the device fasteners  88  are completely clear of engagement with the integral extensions  90 , the load imposed by a fan or fixture hung from the mounting assembly  20  will be supported entirely by the bracket  24 . This provides the advantage that the entire load is supported by the bracket  24 , which is preferably constructed of metal, and not by the electrical box  22 , which may be constructed of plastic. 
   With reference to  FIG. 3 , an opening  98  is provided in the second surface  30   b  of the electrical box  22 . The second portion  32   b  of the bracket  24 , as shown in  FIG. 6 , also includes an opening  100  therein. When the bracket  24  has been secured to the electrical box, as shown in  FIG. 10 , the opening  98  in the second surface  30   b  of the electrical box  22  is in axial alignment with the opening  100  in the second portion  32   b  of the bracket  24 . A snap engagement electrical fitting  102  can be snapped into the opening  98  in the electrical box. With the openings  98  and  100  in axial alignment, electrical wiring (not shown) can be routed through the two openings  98  and  100  and into the inner cavity  84  to supply electricity to the mounting assembly  20 . The snap engagement fitting  102  will grasp the outer surface of any cable inserted therethrough and provide strain relief on the cable to prevent unwanted removal of the cable from the electrical box  22 . 
   The fan and fixture mounting assembly  20  is provided in one piece, as shown in  FIG. 1 , with the bracket  24  secured to the electrical box  22  by fastener  76 . The mounting assembly  20  also includes device fasteners  88  secured in holsters  86 , one of which is in view, and box mounting fasteners  72 , one of which is in view in the figure. The fan and fixture mounting assembly  20  is operated by first placing the mounting assembly  20  against a suitable support (not shown) so that the third portion  32   c  of the bracket  24  is in contact with the support. Box mounting fasteners  72  are then driven into the support to secure the mounting assembly  20  thereto. After the mounting assembly is secured to the support, the device fasteners  88  can be removed from their temporary storage receptacles or holsters  86  and wiring (not shown) fed into the inner cavity  84  and connections completed therein. The mounting ring of the electrical fan or light (not shown) is then raised to the lower edge  104  of the sidewall  26  and aligned thereto. The device fasteners  88  are then passed through the mounting ring of the electrical device and driven into the permanent receptacles  96  to secure the electrical device to the mounting assembly  20 . 
   With reference to  FIG. 2 , the electrical box  22  may be molded of plastic in one piece or constructed of metal. 
   Preferably the bracket  24 , shown in  FIGS. 6–8 , is formed in one-piece from a metal blank  50  such as the one shown in  FIG. 9 . Preferably the blank is formed of steel. 
   As shown in  FIG. 8 , the bracket  24  of the present invention, being constructed from a single piece of metal and having bend angle θ 1  at bend line  52  and bend angle θ 2  at bend line  54 , exhibits superior stiffness for resisting bending forces when supporting a heavy electrical device. The stiffness is further improved by brace members  46  providing bracing action between the second portion  32   b  and third portion  32   c  of the bracket  24 . 
   With reference to  FIG. 7 , the bracing action of the brace members  46  are further improved by the brace members  46  being bent at angle θ 3  along bend lines  56  and the tabs  60  locked into the openings  62  in the third portion  32   c  of the bracket  24 . Crimped areas  64  also increase the stiffness of the bracket  24 . 
   As the invention has been described, it will be apparent to those skilled in the art that the same may be varied in many ways without departing from the spirit and scope of the invention. Any and all such modifications are intended to be included within the scope of the appended claims.