Abstract:
A mounting bracket assembly for hanging a heavy object in a ceiling area comprises a support bar and a clamping component. The support bar telescopes to span a distance between a pair of spaced joists, includes two tubular members which have axes that are parallel and are oriented side-by-side, and an end-plate at each end of the support bar. An overlay for each end-plate includes circular bosses to hold and align preset fasteners, and a slide to adjust the height of the end-plate. The clamping component includes a clamping bar, and at least one fastener that attach the clamping bar to an electrical junction box. When a portion of the support bar is positioned between the clamping bar and the electrical junction box, tightening the fastener that attaches the clamping bar to the electrical junction box will secure the electrical junction box to the support bar.

Description:
CROSS-REFERENCE TO A RELATED APPLICATION  
       [0001]     This application for letters patent is related to and incorporates by reference provisional application for patent serial number 60/778,176, titled “Mounting Bracket ” and filed in the United States Patent and Trademark Office on Mar. 2, 2006. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     This invention relates to a mounting bracket assembly for an electrical fixture. In particular, the invention is a mounting bracket assembly for installing an electrical fixture in a ceiling.  
         [0004]     2. Description of the Prior Art  
         [0005]     An electrical junction box provides a safe enclosure for the electrical wiring that powers an electrical device. For an electrical device hanging from a ceiling, such as a ceiling fan or light fixture, the electrical junction box typically spans between two spaced beams, joists, studs, or the like. A mounting bracket assembly provides the support necessary to suspend the electrical junction box between the two spaced beams, joists, studs, or the like.  
         [0006]     In existing construction where the ceiling is finished drywall, it is desirable for the installer of a ceiling fan or light fixture to minimize or eliminate damage to the remainder of the finished drywall. Typically, the installer can snake the electrical supply wiring through the walls and the ceiling without damaging the finished drywall however, installing the mounting bracket assembly without damaging the finished drywall in more difficult. It is desirable for the installer to make a hole in the finished drywall the size of the electrical junction box and install the mounting bracket assembly through the hole.  
         [0007]     Additionally, the installation of a ceiling fan or light fixture can be an awkward and cumbersome task, especially when performed by a single individual. Often, the installer must work atop a ladder and may not have both hands free to perform the task. A mounting bracket assembly can improve the task of installation of a fixture by making the process easier, more convenient, and save time and expense.  
         [0008]     There is a demand for a mounting bracket assembly that provides greater strength, telescopes to accommodate a span between 14 and 26 inches between two spaced beams, joists, studs, or the like, accommodates various thicknesses of finished drywall, and simplifies the installation process. Consumers have a strong interest in new installation projects due to new home construction, the renovation of existing homes, and seek more choice in the selection of electrical lighting and fan fixtures in the marketplace. Likewise, consumers have a strong interest in doing these renovations on their own, rather than hiring a contractor, to save money. The presently disclosed mounting bracket assembly satisfies these demands.  
       SUMMARY OF THE INVENTION  
       [0009]     A mounting bracket assembly for hanging a heavy object in a ceiling area comprises a support bar and a clamping component. The support bar spans a distance between a pair of spaced joists. The support bar includes two tubular members which have axes that are parallel and which are oriented side-by-side, an inner member, an outer member, and a pair of end-plates. An inside diameter of each tubular member of the outer member of the support bar is greater than an outside diameter of each tubular member of the inner member of the support bar. This allows the tubular members of the outer member of the support bar to receive the tubular members of the inner member of the support bar and enables the support bar to telescope along its lateral axis. One end-plate is located at one end of the inner member and has a surface plane that is substantially perpendicular to a lateral axis of the inner member. The other end-plate is located at one end of the outer member and has a surface plane that is substantially perpendicular to a lateral axis of the outer member. At least two fasteners pass through openings in each end-plate to attach the support bar to the pair of spaced joists. The clamping component includes a clamping bar, and at least one fastener that pass through an opening in the clamping bar and an opening in an electrical junction box. A portion of the support bar is positioned between the clamping bar and the electrical junction box so that tightening said at least one fastener that passes through the opening in the clamping bar will secure the electrical junction box to the support bar.  
         [0010]     If the electrical junction box is fabricated from metal, the inside walls of the tubular members includes grooves that receive the sides of a U-shaped clamping bar and a space between the tubular members receive the fasteners that pass through the openings in the clamping bar. This configuration of the clamping bar and tubular members allows the clamping bar to slide along a lateral axis of the support bar.  
         [0011]     If the electrical junction box is fabricated from plastic or PVC, the electrical junction box includes a channel in the upper wall. The channel includes two shallow side walls and a lower wall. The shallow side walls are perpendicular to the lower wall. The lower surface of the lower wall of the channel is above the lower plane of the electrical junction box to form a cavity under the lower wall of the channel for housing electrical connections in the electrical junction box. The width and depth of the channel are sufficient to receive the support bar and the clamping bar wherein the support bar is positioned between the clamping bar and the lower wall of the channel.  
         [0012]     Each end-plate may include an overlay. The overlay includes an opening for receiving the inner member or the outer member of the support bar, and an opening for receiving each fastener that attaches the support bar to the pair of spaced joists. The overlay may also include a circular boss around the opening for receiving each fastener for holding the fastener and aligning the fastener with the opening in the end-plate thereby simplifying the attachment of the support bar to the pair of spaced joists. The overlay may also include a slide and guides for adjusting the height of the end-plate and electrical junction box above the finished sheetrock. The slide includes a left vertical member, a right vertical member, a horizontal member connecting an upper end of the vertical members, and at least two sets of slots in the upper end of the vertical members, each set of slots including a left slot in the left vertical member and a right slot in the right vertical member. The guides are positioned at a lower edge of the overlay to receive the vertical members of the slide. Two notches positioned near an upper edge of the overlay are positioned to insert into one of the sets of slots in the vertical members of the slide. Inserting the two notches into a lower of the sets of slots disengages the slide thereby using a standard height end-plate, while inserting the two notches into an upper of the sets of slots engages the slide thereby increasing the height of the end-plate. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]      FIG. 1  is an isometric top-view of an exemplary embodiment of the mounting bracket assembly of the present invention.  
         [0014]      FIG. 2  is an exploded view of the mounting bracket assembly shown in  FIG. 1 .  
         [0015]      FIG. 3  is a side elevation of the clamping component of the mounting bracket assembly shown in  FIG. 1 .  
         [0016]      FIG. 4  is a side elevation of the end-plates of the mounting bracket assembly shown in  FIG. 1 .  
         [0017]      FIG. 5  is a top view of the clamping component of the mounting bracket assembly shown in  FIG. 1 .  
         [0018]      FIG. 6  is an exploded view of the clamping component shown in  FIG. 5 .  
         [0019]      FIG. 7  is an isometric top-view of an exemplary embodiment of the mounting bracket assembly of the present invention.  
         [0020]      FIG. 8  is an exploded view of the mounting bracket assembly shown in  FIG. 7 .  
         [0021]      FIG. 9  is a side elevation of the clamping component of the mounting bracket assembly shown in  FIG. 7 .  
         [0022]      FIG. 10  is a top view of the clamping component of the mounting bracket assembly shown in  FIG. 7 .  
         [0023]      FIG. 11  is a side elevation of the clamping component shown in  FIG. 10 .  
         [0024]      FIG. 12  is a bottom view of the clamping component shown in  FIG. 10 .  
         [0025]      FIG. 13  is an exploded view of the clamping component shown in  FIG. 12 .  
         [0026]      FIGS. 14-17  are side elevations of the height adjustable mechanism attached to the telescoping dual tubular support bar near the end-plates of the mounting bracket assembly shown in  FIG. 7 .  
         [0027]      FIGS. 18-19  are exploded views of the height adjustable mechanism shown in  FIGS. 14-17 .  
         [0028]      FIG. 20  is an isometric top-view of the mounting bracket assembly shown in  FIG. 1 .  
         [0029]      FIG. 21  is an isometric top-view of the mounting bracket assembly shown in  FIG. 7 . 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0030]      FIGS. 1-6  illustrate a first exemplary embodiment of the mounting bracket assembly of the present invention. As shown in  FIG. 1 , a mounting bracket assembly  100  includes a telescoping dual tubular support bar  110 , an end-plate  120  at each end of the telescoping dual tubular support bar  110 , and a metal electrical junction box  130  attached to the telescoping dual tubular support bar  110 . The telescoping dual tubular support bar  110  includes two tubular members which have lateral axes that are parallel and which are oriented side-by-side. The end-plates  120  as shown in  FIG. 1  do not include the height adjustable mechanism with the preset fasteners, however adding this mechanism to the end-plates  120  shown in  FIG. 1  shall be understood to one skilled in the art.  FIGS. 2 and 3  illustrate the two components of the telescoping dual tubular support bar  110 , an inner member  112  and an outer member  114 . An inside diameter of each tubular member of the outer member  114  is greater than an outside diameter of each tubular member of the inner member  112 . The tubular members of the inner member  112  receive and slide inside the tubular members of the outer member  114  to provide the telescoping nature of the dual tubular support bar  110 .  FIG. 2  also shows the clamping component  140  that attaches the metal electrical junction box  130  to the telescoping dual tubular support bar  110 .  FIG. 3  shows the clamping component  140  as including a U-shaped bar  142  that slides inside grooves on the inside walls of the tubular members of the inner member  112  and outer member  114  of the telescoping dual tubular support bar  110 . The U-shaped bar  142  includes two riveted fasteners  144  that attach the metal electrical junction box  130  to the U-shaped bar  142 . Tightening the two riveted fasteners  144  secures the metal electrical junction box  130  to the dual tubular support bar  110  and prevents the metal electrical junction box  130  from sliding on the dual tubular support bar  110 . In addition, the tightening also increases the vertical and horizontal strength of the dual tubular support bar  110 .  FIG. 4  shows the relationship between the telescoping dual tubular support bar  110  and the end-plates  120 . Each end-plate  120  attaches to one end of either the inner member  112  or the outer member  114 . The opposite end of the inner member  112  is then free to slide into the end of the outer member  114  opposite the other end-plate  120 .  FIGS. 5 and 6  illustrate the relationship between the metal electrical junction box  130  and the clamping component  140 . The two riveted fasteners  144  each pass through an opening in the U-shaped bar  142  and an opening  134   a  in the metal electrical junction box  130  and are secured via a stopper (not shown) such as a nut. Alternatively, the installer may change the orientation of the metal electrical junction box  130  by passing the two riveted fasteners  144  through other openings  134   b  in the electrical junction box  130 .  
         [0031]      FIGS. 7-13  illustrate a second exemplary embodiment of the mounting bracket assembly of the present invention. As shown in  FIG. 7 , the mounting bracket assembly  200  includes a telescoping dual tubular support bar  210 , an end-plate  220  at each end of the telescoping dual tubular support bar  210 , and a plastic or polyvinyl chloride (PVC) electrical junction box  230  attached to the telescoping dual tubular support bar  210 . The telescoping dual tubular support bar  210  includes two tubular members which have lateral axes that are parallel and which are oriented side-by-side. Attached to each end-plate  220  shown in  FIG. 7  is a height adjustable mechanism  250  including preset fasteners  252 .  FIGS. 8 and 9  illustrate the two components of the telescoping dual tubular support bar  210 , an inner member  212  and an outer member  214 . An inside diameter of each tubular member of the outer member  214  is greater than an outside diameter of each tubular member of the inner member  212 . The tubular members of the inner member  212  receive and slide inside the tubular members of the outer member  214  to provide the telescoping nature of the dual tubular support bar  210 .  FIG. 9  also shows the clamping component  240  that attaches the plastic or PVC electrical junction box  230  to the telescoping dual tubular support bar  210 . The clamping component  240  includes a U-shaped bar  242  that slides outside the outer member  214  of the telescoping dual tubular support bar  210 . The dual tubular support bar  210  slides in a channel  232  in the plastic or PVC electrical junction box  230  below the U-shaped bar  242 . The channel  232  includes two shallow side walls and a lower wall. The shallow side walls are perpendicular to the lower wall. The lower surface of the lower wall of the channel is above the lower plane of the plastic or PVC electrical junction box  230  to form a cavity under the lower wall of the channel for housing electrical connections in the plastic or PVC electrical junction box  230 . The width and depth of the channel are sufficient to receive the dual tubular support bar  210  and U-shaped bar  242 . The U-shaped bar  242  includes two riveted fasteners  244  and a center riveted fastener  246 . The center riveted fastener  246  attaches the plastic or PVC electrical junction box  230  to the U-shaped bar  242 . The two riveted fasteners  244  pass through the plastic or PVC electrical junction box  230  to provide the threaded supports that attach the ceiling fixture (not shown) to the plastic or PVC electrical junction box  230 . Tightening the plastic or PVC electrical junction box  230  to the U-shaped bar  242  secures the plastic or PVC electrical junction box  230  to the dual tubular support bar  210  and prevents the plastic or PVC electrical junction box  230  from sliding on the dual tubular support bar  210 . In addition, the tightening also increases the vertical and horizontal strength of the dual tubular support bar  210 .  FIGS. 10 and 11  illustrate the relationship between the plastic or PVC electrical junction box  230  and the clamping component  240  including the channel  232  in the plastic or PVC electrical junction box  230  and the two riveted fasteners  244  and center riveted fastener  246  with the U-shaped bar  242 .  FIGS. 12 and 13  illustrate the interior of the plastic or PVC electrical junction box  230 , the clamping component  240 , and the threaded supports  244  that attach the ceiling fixture to the plastic or PVC electrical junction box  230 .  
         [0032]     The first and second exemplary embodiment of the mounting bracket assembly  100 ,  200  may be inserted in the space in a ceiling between two spaced beams, joists, studs, or the like. The telescoping dual tubular support bar  110 ,  210  spans the two spaced beams, joists, studs, or the like and secures to the two spaced beams, joists, studs, or the like by the use of the two endplates  120 ,  220 . The telescoping dual tubular support bar  110 ,  210  provides added strength for securing a load (e.g., weight of a ceiling fixture) and stability (e.g., resistance against torsion). This is especially important with any fixture that is heavy or has rotating parts, such as a modern ceiling fan.  
         [0033]      FIGS. 14-19  illustrate an exemplary embodiment of a height adjustable mechanism that attaches to the telescoping dual tubular support bar near the end-plate on the mounting bracket assembly of the present invention.  FIG. 14  shows two embodiments of the height adjustable mechanism attached to the telescoping dual tubular support bar near the end-plate on the mounting bracket assembly. The left side of  FIG. 14  shows the height adjustable mechanism  320  attached to the telescoping dual tubular support bar  350  near the end-plate  310 . The height adjustable mechanism  320  is engaged to raise the height of the end-plate  310  which raises the height of the electrical junction box (not shown) that attaches to the telescoping dual tubular support bar  350  and allows the mounting bracket assembly to accommodate thinner finished drywall (e.g., ½ inch thick drywall). The right side of  FIG. 14  shows the height adjustable mechanism  340  attached to the telescoping dual tubular support bar  352  near the end-plate  330 . The height adjustable mechanism  340  is disengaged to use the standard height of the end-plate  330  which sets the height of the electrical junction box (not shown) that attaches to the telescoping dual tubular support bar  352  to the standard height and allows the mounting bracket assembly to accommodate thicker finished drywall (e.g., ⅝ inch thick drywall).  FIGS. 15-17  show the two embodiments shown in  FIG. 14  from other perspectives.  
         [0034]      FIG. 18  shows the two components of the height adjustable mechanism  320  attached to the telescoping dual tubular support bar  350  near the end-plate  310 , an overlay  321  and a slide  324 . The left and right vertical members of the slide  324 , as shown, include two slots  326   a ,  326   b . When the installer moves the slide  324  to select the top slot  326   a , the height adjustable mechanism  320  is engaged. When the installer moves the slide  324  to select the bottom slot  326   b , the height adjustable mechanism  320  is disengaged. In other embodiments, the number of slots and the position of the slots will vary to accommodate various height adjustments for the height adjustable mechanism  320 .  FIG. 19  shows the guides  327  in the overlay  321  that receive the left and right vertical members of the slide  324 . The left and right vertical members of the slide  324  pass through and the guides  327  and the notches  328  in the overlay  321  pass through one of the sets of slots  326   a ,  326   b  in the vertical members of the slide  324  to allow the installer to either engage or disengage the height adjustable mechanism  320 .  
         [0035]     The first and second embodiment of the mounting bracket assembly  100 ,  200  each may include the height adjustment mechanism  320 . The height adjustable mechanism  320  contributes to the ease and convenience of installation of a ceiling fixture. The height adjustable mechanism  320  allows the mounting bracket assembly to be spaced at the appropriate distance from the ceiling, in a level fashion, and at the proper orientation (e.g., parallel to the ceiling level).  
         [0036]      FIGS. 15-19  also illustrate an exemplary embodiment of preset fasteners  322 ,  342 , such as screws, on the height adjustable mechanism  320 ,  340  attached to the telescoping dual tubular support bar  350  near the end-plate  310  on the mounting bracket assembly of the present invention.  FIGS. 15-18  show several perspectives of the preset fasteners  322 ,  342  inserted in a circular boss  323  on each end of the overlay  321  and positioned to attach the mounting bracket assembly to the two spaced beams, joists, studs, or the like.  FIG. 19  shows that the preset fasteners  322 ,  342  are preset in circular boss  323  of the overlay  321  that is perpendicular to the interior face of the overlay  321 . The preset fasteners  322 ,  342  contribute to the ease and convenience of the installation process.  
         [0037]      FIG. 20  illustrates an exemplary embodiment of the extended span capability of the mounting bracket assembly  100  illustrated in  FIGS. 1-6 .  FIG. 20  shows the dual tubular support bar  110  which telescopes to accommodate a span between 14 and 26 inches between two spaced beams, joists, studs, or the like. The clamping component  140  that attaches the metal electrical junction box  130  to the dual tubular support bar  110  slides along the dual tubular support bar  110  to position the metal electrical junction box  130  at the most desirable position. When the attachment between the metal electrical junction box  130  and the dual tubular support bar  110  is tightened, the clamping component  140  also provides additional strength to the dual tubular support bar. The additional strength is maximized when the clamping component  140  is tightened on the portion of the dual tubular support bar that includes both the inner member  112  and the outer member  114  of the dual tubular support bar  110 .  
         [0038]      FIG. 21  illustrates an exemplary embodiment of the extended span capability of the mounting bracket assembly  200  illustrated in  FIGS. 7-13 .  FIG. 21  shows the dual tubular support bar  210  which telescopes to accommodate a span between 14 and 26 inches between two spaced beams, joists, studs, or the like. The clamping component  240  that attaches the plastic or PVC electrical junction box  230  to the dual tubular support bar  210  slides along the dual tubular support bar  210  to position the plastic or PVC electrical junction box  230  at the most desirable position. When the attachment between the plastic or PVC electrical junction box  230  and the dual tubular support bar  210  is tightened, the clamping component  240  also provides additional strength to the dual tubular support bar  210 . The additional strength is maximized when the clamping component  240  is tightened on the portion of the dual tubular support bar  210  that includes both the inner member  212  and the outer member  214  of the dual tubular support bar  210 .  
         [0039]     Although the disclosed exemplary embodiments describe a fully functioning mounting bracket assembly, the reader should understand that other equivalent exemplary embodiments exist. Since numerous modifications and variations will occur to those reviewing this disclosure, the mounting bracket assembly is not limited to the exact construction and operation illustrated and disclosed. Accordingly, this disclosure intends all suitable modifications and equivalents to fall within the scope of the claims.