Abstract:
A prepackaged mounting assembly for securing a ceiling fan, light fixture, or similar device to an overhead beam. The prepackaged assembly securely holds all the hardware needed for attaching the mounting block to a beam, including fasteners and a junction box cover, without the need for an outer wrap or separate packaging for each separate mounting assembly. Several mounting assemblies can therefore be placed loosely in a large packaging container and stored and shipped without loss of the separate parts for each assembly. The L-shaped mounting assembly provides a significantly larger integral internal wiring cavity than those provided in prior art assemblies. The internal cavity includes a cover that is temporarily secured to the assembly for storage and shipment and may be removed and reinstalled after wiring connections are completed within the cavity. After being reinstalled on the mounting assembly, the cover protects the wiring connections within from application of sheet rock, spackle, paint, and other subsequent operations. After initial installation, removing the cover enables easy access to wiring connections without dropping the suspended fixture.

Description:
FIELD OF THE INVENTION 
     The present invention relates to mounting assemblies for securing a device, such as a ceiling fan, light fixture, or similar device to an overhead beam and particularly to an L-shaped mounting assembly that provides an integral internal cavity for completing and holding wire connections that is significantly larger than prior art devices. The internal cavity includes a cover that is temporarily secured to the assembly for storage and shipment and may be removed and reinstalled after wiring connections are completed within the cavity. After being reinstalled on the mounting assembly, the cover protects the wiring connections from application of sheet rock, spackling, and painting around the assembly. Fasteners are provided with and secured to the box during storage and shipment to provide the installer a prepackaged mounting assembly with all required hardware included. At the assembly site, the fasteners are easily repositioned and used to secure the mount assembly to an overhead support member and a fixture to the mount assembly. 
     BACKGROUND OF THE INVENTION 
     Mounting structures for ceiling-suspended electrical devices are sometimes sold as a prepackaged unit including fasteners and a protective cover. For example, U.S. Pat. No. 5,762,223 (hereinafter the &#39;223 patent) provides an electrical junction box to be used when supporting a relatively heavy hanging load from a joist or beam at an installation site. In one embodiment, a pancake dish and electrical lead box are integrally joined as a unit for direct joist mounting or can be utilized with a bracket. Although the &#39;223 patent adequately provides a mounting structure capable of supporting large dynamic and static loads, the internal volume of the electrical lead box is severely restricted thereby making it difficult to complete and comfortably fit wiring connections within the electrical lead box. In addition, the &#39;223 patent provides a removable plastic cover that is held on the lower apron of the mounting assembly by a frictional fit and mounting screws that are secured to the mounting assembly by a frictional fit between semi-circular dependent posts and annular vertical bosses. Although held by a frictional fit, the removable cover and mounting screws can easily be jarred loose during shipment, making it necessary to wrap the mounting assembly or provide an outer package to hold the cover and mounting screws inside the assembly during storage and shipment. 
     Accordingly, to overcome deficiencies in prior art mounting structures, it will be a first object of the present invention to provide a mounting structure having a large cavity for wiring connections. A second object includes providing a mounting structure that is capable of being stored, shipped, and sold as a prepackaged unit with all covers and fasteners required for installation self-contained within the unit. The cover and fasteners will be held securely enough to permit storage, shipping, display and without the need for an outer wrap or separate packaging. 
     SUMMARY OF THE INVENTION 
     According to the present invention, there is provided a mounting assembly for securing a device, such as a ceiling fan, light fixture, or similar device to an overhead beam. The mounting assembly includes an L-shaped mounting box that is fitted against an overhead beam with two sides, perpendicular to each other, in contact with the beam. A large integral internal cavity is provided for wiring connections. A cover, provided for the internal wiring cavity, is temporarily secured to the assembly for storage and shipment. Fasteners, required for mounting the box to a beam and a fixture bracket to the box, are also temporarily secured to the L-shaped box for storage and shipment. The L-shaped mounting assembly therefore includes the L-shaped box with an integral wiring cavity, a cover for the cavity, and fasteners for use in installing the box. The mounting assembly may be stored, shipped, and sold as a self-contained unit, without the need for an outer wrap or separate packaging. 
     At the installation site, all required items for mounting the L-shaped box are included with the assembly. An initial mounting fastener is used to anchor the box to an overhead beam. The cover may then be removed and reinstalled after wiring connections are completed within the cavity. After being reinstalled on the mounting box, the cover protects the wiring connections from application of sheet rock, spackle, and paint around the fixture. Fixture mounting fasteners, provided with the mounting assembly, are then removed from temporary storage holsters and moved to the proper location to secure a bracket for a ceiling fan, overhead light, or similar device. 
     Other advantages of the present invention will become apparent by reading the attached description with reference to the attached drawings. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of the mounting assembly with the cover exploded away from the mounting box. 
     FIG. 2 is a bottom view of the mounting assembly of FIG.  1 . 
     FIG. 3 is a side view of the mounting assembly of FIG. 1 in phantom lines and showing the relative location of the self-contained fasteners included with the assembly. 
     FIG. 4 is a side sectional view of an integral screw-retaining boss included with the mounting assembly of FIG.  1 . 
     FIG. 5 is a side sectional view of the screw-retaining boss of FIG. 4 with a screw inserted partially in the boss. 
     FIG. 6 is a side sectional view of the mounting assembly of FIG.  1 . 
     FIG. 7 is a perspective view of the mounting assembly of FIG. 1 after it has been initially mounted on a support beam by an initial mounting fastener and with the fixture bracket fasteners seated in their holsters. 
     FIG. 8 is a perspective view of the mounting assembly of FIG. 1 after being completely secured to a support beam by both the initial mounting fastener and the fixture bracket fastener. 
    
    
     TABLE OF NOMENCLATURE 
     The following is a listing of part numbers used in the drawings along with a brief description: 
     
       
         
               
               
               
             
           
               
                   
                   
               
               
                   
                 Part Number 
                 Description 
               
               
                   
                   
               
             
             
               
                   
                 10 
                 prepackaged mounting assembly 
               
               
                   
                 12 
                 cover 
               
               
                   
                 14 
                 first junction box 
               
               
                   
                 16 
                 internal wiring cavity 
               
               
                   
                 18 
                 deep side walls 
               
               
                   
                 20 
                 first side 
               
               
                   
                 21 
                 inner wall (of first side) 
               
               
                   
                 22 
                 second junction box 
               
               
                   
                 24 
                 top (of second junction box) 
               
               
                   
                 26 
                 vertical face (of first side) 
               
               
                   
                 28 
                 seat 
               
               
                   
                 30 
                 edges (of three side walls) 
               
               
                   
                 32 
                 shallow side walls 
               
               
                   
                 34 
                 open area 
               
               
                   
                 36 
                 apertures (in top) 
               
               
                   
                 38 
                 boss (for initial mounting fastener) 
               
               
                   
                 40 
                 initial mounting fastener 
               
               
                   
                 42 
                 elongated slots 
               
               
                   
                 44 
                 fixture bracket fastener 
               
               
                   
                 46 
                 first arcuate flange (of second junction box) 
               
               
                   
                 48 
                 second arcuate flange (of cover) 
               
               
                   
                 50 
                 boss (to accept cover fastener) 
               
               
                   
                 52 
                 cover fastener 
               
               
                   
                 54 
                 aperture (in ear) 
               
               
                   
                 56 
                 ear 
               
               
                   
                 58 
                 circular mounting surface 
               
               
                   
                 60 
                 holster 
               
               
                   
                 62 
                 knockout 
               
               
                   
                 64 
                 low profile connector 
               
               
                   
                 66 
                 top (of first junction box) 
               
               
                   
                 68 
                 top inner bore (of holster) 
               
               
                   
                 68A 
                 interior surface (of top inner bore) 
               
               
                   
                 70 
                 bottom inner bore (of holster) 
               
               
                   
                 70A 
                 interior surface (of bottom inner bore) 
               
               
                   
                 72 
                 point (of fixture bracket fastener) 
               
               
                   
                 74 
                 support beam 
               
               
                   
                   
               
             
          
         
       
     
     DETAILED DESCRIPTION 
     A perspective view of a preferred embodiment of the present invention, a prepackaged mounting assembly  10  with the cover  12  detached, is shown in FIG.  1 . The mounting assembly  10  includes a first junction box  14  with an internal wiring cavity  16 , and deep side walls  18 . Integral with and projecting orthogonally from a first side  20  of the first junction box  14  is a second junction box  22  in such a manner that the top  24  of the second junction box  22  and the vertical face  26  of the first side  20  form a seat  28  for fitting flush against a side and bottom of a beam or joist (not shown). The edges  30  of three side walls opposite the first side  20  end in a common lower plane. Shallow side walls  32  extend downward from the top  24  of the second junction box  22  on all sides away from the first junction box  14  leaving an open area  34  for the passage of wires (not shown) between the first  14  and second junction  22  boxes. Apertures  36  are included in the top  24  of the second junction box  22  for receiving fasteners for securing the mounting assembly to a beam or joist (not shown) including a boss  38  for receiving an initial mounting fastener  40  and elongated slots  42  for receiving fixture bracket fasteners  44 . A first arcuate flange  46  is integral with and extends laterally from the shallow side walls  32  of the second junction box  22 . A second arcuate flange  48  is integral with and extends downward from the cover  12 . The side walls  18  of the first junction box  14  include bosses  50  (one shown) that will accept cover fasteners  52  that secure the cover  12  through apertures  54  in ears  56 . After the cover  12  is attached by cover fasteners  52 , the second arcuate flange  48  will mate with the first arcuate flange  46  of the second junction box  22  to form a circular mounting surface  58  that will accept a bracket (not shown) of a ceiling fan, light, or similar device. Provision is made for temporary storage of the fixture bracket fasteners  44  during shipment and storage by including integral holsters  60  molded along the inner wall of the first junction box  14  on the first side  20 . 
     Referring to the bottom view of the mounting assembly  10  in FIG. 2, fixture bracket fasteners  44  are shown seated in their holsters  60  along the inner wall  21  of the first side  20  of the first junction box  14 . The holsters  60  are integral with and project from the first side  20  into the internal wiring cavity  16 . One advantage of the prepackaged mounting assembly  10  is its large wiring cavity  16 , which becomes apparent when viewing FIG.  2 . Prior art L-shaped mounting blocks are typically circular in shape with the junction box conforming to the circular limits of the bottom flange and thereby limiting the size of the wiring cavity. In the present invention, as shown in FIG. 2, the first junction box  14  extends beyond the circular mounting surface  58  created by the first  46  and second  48  arcuate flanges. Other details of the arrangement of the mounting assembly  10  shown in FIG. 2 include a knockout  62  in the second junction box  22 , a low profile connector  64  located in the top  66  of the first junction box  14 , elongated slots  42  through which the fixture bracket fasteners  44  will later be mounted, and cover fasteners  52  which will secure the cover  12  to the first junction box  14  through apertures  54  in ears  56 . The initial mounting fastener  40  is shown seated in its boss  38  that is an integral extension from the second junction box  22 . 
     Referring to FIG. 3, a side view of the prepackaged mounting assembly  10  in phantom lines shows the relative location of the self-contained fasteners during shipment and storage including the cover fasteners  52  seated in their bosses  50 , the initial mounting fastener  40  seated in its boss  38 , and the fixture bracket fasteners  44  seated in the holsters  60 . During installation of the box, the cover fasteners  52  and initial mounting fastener  40  will be used at their storage location but the fixture bracket fasteners  44  will be removed from their temporary storage position in the holsters  60  and secured to the supporting beam or joist (not shown) through the elongated slots  42  (not shown). 
     Referring to FIG. 4, a side sectional view is shown of a screw-retaining holster  60  that will be used to hold a fixture mounting screw (not shown) for shipment with the electrical box to a job site. As used within this disclosure, a holster  60  is defined as an enclosure integral with a fixture mounting box for frictionally holding a threaded fastener so that it does not become separated from the box during storage and shipment, including a central bore open on at least one end for receipt of the threaded fastener and preferably closed on its second end for protecting the end of the threaded fastener. The central bore of the holster  60  includes a top inner bore  68  and a bottom inner bore  70  with the top inner bore  68  of a larger diameter than the bottom inner bore  70 , as shown in FIG.  4 . Top inner bore  68  includes interior wall  68 A and bottom inner bore  70  includes interior wall  70 A. 
     Referring to FIG. 5, for use with a #12×2-inch sheet metal screw or fixture bracket fastener  44  the top inner bore  68  of the holster  60  typically measures 0.250 inch and the bottom inner bore  70  typically measures 0.187 inch. Preferably, the interior wall  68 A of the top inner bore  68  and the interior wall  70 A of the bottom inner bore  70  of each holster  60  is smooth. A smooth surface  68 A on the top inner bore  68  enables the fixture bracket fastener  44  to easily slip into the holster  60  presenting no obstruction to the fastener  44  as it moves therein. A smooth surface  70 A on the bottom inner bore  70  enables the fixture bracket fastener  44  to rapidly and easily self-tap and make its own thread. The combination of the smooth surface  68 A and dimensions of the top inner bore  68  allows the fixture bracket fastener  44 , with a nominal major thread diameter of 0.2115 inch, to enter the top inner bore  68  easily. The fixture bracket fastener  44  can then be screwed partially into the bottom inner bore  70 , where it makes its own threads in the smooth surface  70 A, and can be advanced until it is held securely for shipment. The fixture bracket fastener  44  can then easily be removed by an installer at the job site and repositioned to the proper location to secure a ceiling fan or other fixture to a rafter through one of the elongated slots (not shown in FIG.  5 ). 
     As shown in FIG. 5, once inserted in the holster  60 , the point  72  of the fixture bracket fastener  4  is enclosed within and protected by the holster  60 . The holsters  60  therefore protect the ends or points  72  of the fixture bracket fasteners  44  during storage and shipment of the box. The prepackaged mounting assembly  10  of this disclosure may have relatively deep side walls  18  as shown in FIG. 6 or it may be manufactured with deeper or shallower side walls as desired for the specific application. When mounted within the holsters  60  for shipment and storage, essentially the entire length of the fixture bracket fastener  44  is recessed within and protected by the side walls  18  of the mounting assembly  10 , as shown in the side sectional view of FIG.  6 . The side walls  18  can be made deeper if preferred to provide more space for electrical connections or shallower if desired. For shallower boxes, the holsters  60  typically can extend from the top  66  of the first junction box  14  and accommodate the point  72  and essentially the entire length of the fixture bracket fastener  44 . 
     The purpose and utility of the holsters  60  is to provide a location for the placement of fixture bracket fasteners  44  during shipment and prior to installation. The fixture bracket fasteners  44  may be screws, bolts, or similar fasteners. As is well recognized by those employed in the electrical trades, mounting bolts or screws for the attachment of ceiling fans or other electrical fixtures are often misplaced or left at a position remote from the installation site, for example on the floor, requiring time and effort to locate the screws or bolts or the acquisition of replacements to complete an installation. The inclusion of mounting bolts or screws, frictionally engaged in holsters  60  assures the immediate availability of such fasteners at the appropriate time in the installation process. Similarly, it is contemplated that the initial mounting fastener  40  that is used to initially fasten the mounting assembly  10  to a beam or joist (not shown) through screw-retaining boss  38  be similarly included by frictional engagement in boss  38  during shipping and prior to installation as shown in FIG.  1 . 
     Referring to FIG. 7, a preferred embodiment of the prepackaged mounting assembly  10  is depicted after it has been initially mounted on a support beam  74  by the initial mounting fastener  40 . An installer typically receives the prepackaged mounting assembly  10  with the initial mounting fastener  40  secured in its boss  38 , the fixture bracket fasteners  44  are secured in their holsters  60 , and the cover fasteners  52  secured in their bosses  50  (one of which is in view in FIG.  7 ). To install the prepackaged mounting assembly  10 , an installer typically first removes the initial mounting fastener  40  from its boss  38  and places the mounting assembly  10  against a support beam  74  with the seat  28 , consisting of the vertical face  26  of the first side  20  and top  24  of the second junction box  22 , flush against the beam  74 , as shown in FIG.  7 . The installer can then drill a hole in the beam  74  through the inner bore of boss  38  and secure the mounting assembly  10  to the beam  74  by tightening the initial mounting fastener  40  through its boss  38  into the beam  74 . An installer would then drill pilot holes into the beam  74  through the two elongated slots  42  in the desired location to match the hole spacing in the fixture bracket (not shown). The fixture bracket fasteners  44  would then typically be removed one at a time from their holsters  60 , one each placed through each of the fixture brackets (not shown) and tightened into the pilot holes at the elongated slots  42 . The installer would next typically remove the cover  12  from the first junction box  14  and feed electrical cable from the house wiring system into the first junction box  14  through one of the available knockouts (not shown). The fixture would then typically be anchored to the bracket and the wiring leads from the fixture passed through the open area  34  fro m the second junction box  22  into the first junction box  14 . Wiring connections can then be completed for the intended fixture by connecting house wiring to the fixture leads within the first junction box  14 . The cover  12  can then be secured to the first junction box  14 . If required for troubleshooting or repair, the cover  12  may easily be removed at anytime in the future to provide access to the wiring within the first junction box  14  without first dropping or removing the suspended fixture. This is an advantage over prior art L-shaped mounting assemblies. In prior art L-shaped boxes, the upright junction box is within the confines of the circular mounting surface, and access may be obtained to the wiring connections only by dropping or removing the fixture. 
     By providing a prepackaged mounting assembly  10 , the installer avoids having to search for the proper fasteners for the job. The correct fasteners are available with the mounting block when required. Additionally, the required fasteners are held securely within the mounting block until needed, thereby allowing the distributor to package a number of prepackaged mounting assemblies in a shipping container. It is very common and desirable for distributors to package a large number of electrical devices loosely in a container as it eliminates outer wrap or packaging for each individual device making it easy for a contractor to purchase a container of prepackaged mounting assemblies and pull them out when needed. Since each individual device is loose in the shipping container, the contractor would not be inconvenienced with the task of removing outer wrap or individual packaging from each. Packing a number of the mounting assemblies loosely within a box is also attractive to the hardware superstores that prefer to place the opened containers on store shelves for easy access by store customers. Home owners benefit by having easy access to the prepackaged mounting assemblies and by not having to search for the proper fasteners. 
     Referring to FIG. 8, a perspective view is shown of the mounting assembly  10  of FIG. 1 after being completely secured to a support beam  74  by both the initial mounting fastener  40  and the fixture bracket fasteners  44 . A fixture bracket, normally supplied by the fixture manufacturer, would typically be fastened to the mounting assembly  10  by the fixture bracket fasteners  44 , but is not included in FIG. 8 for clarity. As shown in FIG. 8 as compared to FIG. 7, the fixture bracket fasteners  44  have been moved from their temporary storage positions in the holsters  60  and mounted through the elongated slots  42  (edges visible only) where they both anchor the mounting assembly  10  and hold the fixture bracket (not shown) secure to the beam  74 . As previously mentioned, the preferred fixture bracket fasteners  44  are typically #12×2″ sheet metal screws, making the fixture bracket fasteners  44  the main anchoring means for supporting the static and dynamic loads created by a typical 70 to 100 pound ceiling fan or similar fixture. The initial mounting fastener  40  also assists in supporting the load and is preferably a #10×1″ sheet metal screw. 
     As shown in FIG. 8, once the cover  12  is secured to the first junction box  14 , it forms a portion of the circular mounting surface  58  to which a fixture bracket (not shown) will be secured. In prior art mounting assemblies, the mounting block typically has a circular profile with the upright junction box within the confines of the overall circular profile. The cover in prior art mounting assemblies is typically circular and covers the entire bottom portion of the mounting block, including the junction box. With prior art mounting assemblies, the frictional fitting cover must be removed and then retained while wiring connections are made within the junction box. The cover must then be placed upon the lower apron of the mounting block where it must be held by friction as sheet rock and then paint is applied. With the present invention, once wiring connections are completed and the cover  12  is secured to the first junction box  14 , it is left in place and the second arcuate flange  48  on the cover  12  is obscured from view by the fixture (not shown) suspended below it. When the mounting assembly  10  is anchored to a joist, sheet rock may be applied around the mounting assembly  10  to completely obscure the cover  12  or it may be applied so as not to obscure the cover  12  and therefore keep the cover  12  accessible. By extending the first junction box  14  beyond the original confines of the circular mounting surface  58  and providing a cover  12  that covers only the first junction box  14 , the internal wiring cavity provided by the present invention is much larger in volume than those of the prior art. A second advantage provided by a separate cover  12  for the first junction box  14  is that the internal wiring cavity  16  may be accessed after initial installation of the ceiling fixture without having to remove the fixture itself. Typically, if anchored to a joist, some sheet rock may have to be removed and replaced, but the fixture itself can remain secured to the first arcuate flange  46  on the second junction box  22 . In prior art mounting assemblies, the junction box is confined within the circular perimeter of the mounting block, and therefore access to the wiring cavity is obtained only by removing the fixture from the mounting block. 
     As previously mentioned, one of the advantages of the mounting assembly of the present invention over the prior art is the large volume of the internal wiring cavity of the first junction box. Referring to FIG. 6, the typical dimensions of the internal wiring cavity  16  of a preferred embodiment of the prepackaged mounting assembly  10  of the present invention include a width, between the two side walls  18 , of 1.7 inches, a length of 4.0 inches, and a depth of 3.2 inches. The internal wiring cavity  16  of the first junction box  14  therefore provides approximately 22 cubic inches of volume for wiring connections. This compares to an approximate 9.0 cubic inch volume for prior art L-shaped mounting assemblies. 
     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 included within the scope of the appended claims.