Abstract:
A recessed low voltage mounting assembly including a low voltage mounting bracket and a trim plate for installing a low voltage electrical component in either old work or new construction. Two options are provided for mounting the assembly to the wall. In new construction, two captive fasteners in the mounting bracket are available to be driven into a stud or other framework of the building. In an old work situation, rotatable flags are provided for securing the assembly to the wall. Adjustment screws for rotating and tightening the flags are accessible through apertures in the trim plate. The assembly recesses the low voltage component behind the wall surface, thereby enabling placement of low voltage devices in close proximity to the wall and mounting assembly. A second embodiment provides a one-piece version of the low voltage mounting assembly in which the trim plate is integral with the bracket.

Description:
This application is a Continuation of U.S. patent application Ser. No. 11/980,063 filed Oct. 30, 2007, now U.S. Pat. No. 7,435,900, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/655,299 filed Jan. 19, 2007, now U.S. Pat. No. 7,294,781, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/356,590 filed Feb. 16, 2006 and now U.S. Pat. No. 7,166,801, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/264,857, filed Nov. 2, 2005 and now U.S. Pat. No. 7,045,713, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/246,985, filed Oct. 7, 2005 and now U.S. Pat. No. 7,064,271, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/185,256, filed Jul. 20, 2005 and now U.S. Pat. No. 7,115,820, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/102,392, filed Apr. 8, 2005 and now U.S. Pat. No. 7,151,219, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/070,344, filed Mar. 2, 2005 and now U.S. Pat. No. 6,965,078, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/009,116 filed Dec. 10, 2004 and now U.S. Pat. No. 7,005,578, which is a Continuation-In-Part of U.S. patent application Ser. No. 10/863,942 filed Jun. 9, 2004 and now U.S. Pat. No. 6,956,171, all of which are commonly owned by the assignee of the present invention and the entire contents of which are incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to electrical junction boxes and specifically to a recessed low voltage mounting assembly that recesses a low voltage electrical component within the wall of a building. 
     BACKGROUND OF THE INVENTION 
     Recessed electrical boxes for retrofitting on finished walls or for use in new construction were disclosed in U.S. Pat. Nos. 6,965,078, 6,956,171, 7,005,578, 7,045,713, 7,064,271, 7,115,820, 7,151,219, 7,166,801, and 7,294,781, and in co-pending U.S. application Ser. No. 11/980,063, all of which are commonly owned by the assignee of the present invention and the entire contents of which are incorporated herein by reference. 
     The recessed electrical boxes disclosed in the aforementioned patents and applications comprised an electrical box having an inner enclosure for housing an electrical device and an outer enclosure for recessing the inner enclosure well within a wall. The recessed electrical box including the inner enclosure and outer enclosure were either integrally formed in one piece or provided in two pieces each formed of the same material of construction. 
     Although a recessed electrical box of the type described in the aforementioned disclosures provided an adequate means for recessing an electrical device substantially within the wall of a structure, they were directed primarily to recessing high voltage devices within the wall of a building. Although the aforementioned patents and patent application provide an apparatus for recessing a high voltage device within the wall of a structure, there is also a need for recessing a low voltage device within wall of a structure. 
     Accordingly, the present invention provides a recessed low voltage mounting assembly that includes a first portion that comprises a low voltage mounting bracket for securing to a wall and housing and protecting a low voltage device and its associated wiring. A second portion of the recessed low voltage mounting assembly includes a trim plate for covering the low voltage mounting bracket and a portion of the wall surrounding the bracket to obscure that portion of the wall surrounding the low voltage device. 
     SUMMARY OF THE INVENTION 
     The invention is a recessed low voltage mounting assembly including a low voltage mounting bracket and a trim plate for installing a low voltage electrical component in either old work or new construction. A first embodiment of the assembly includes two options for mounting to the wall. In new construction, two captive fasteners in the mounting bracket can be driven into a stud or other framework of the building. The trim plate is then secured to the mounting bracket to provide an attractive recessed area for enclosing a low voltage component. In an old work situation, rotatable flags are provided for securing the assembly to the wall. Adjustment screws for rotating and tightening the flags are accessible through apertures in the trim plate. The trim plate includes a laterally extending flange that covers the wall surface surrounding the bracket and enables blocking the unsightly boundary area between the bracket and wall. The assembly recesses the low voltage component behind the wall surface, thereby enabling placement of low voltage devices in close proximity to the wall and mounting assembly. A second embodiment provides a one-piece version of the low voltage mounting assembly in which the trim plate is integral with the bracket. 
     OBJECTS AND ADVANTAGES 
     Several advantages are achieved with the recessed low voltage mounting assembly of the present invention, including:
         (1) A first advantage of the recessed low voltage mounting assembly is that it properly recesses a low voltage component at the proper depth from the wall surface.   (2) The assembly provides a means of recessing low voltage components from the wall surface thereby enabling placement of low voltage components in close proximity to the wall.   (3) A two piece embodiment of the assembly enables recessing of a low voltage component in either an old work or new construction situation.   (4) A two piece embodiment of the assembly provides two fastening options for added convenience in mounting the assembly to the wall including captive fasteners for new construction and rotatable flags for an old work installation.   (5) The rotatable flags are accessible from the front of the assembly to enable tightening of the low voltage assembly to the wall after initial installation if desired or remounting of the assembly if a new wall covering or layer is installed.   (6) A one piece version of the assembly can be manufactured at lower cost and includes rotatable flags primarily for an old work installation.       

     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 front exploded perspective view of a recessed low voltage mounting assembly according to the present invention. 
         FIG. 2  is a front elevation view of the recessed low voltage mounting assembly of  FIG. 1 . 
         FIG. 3  is a side view of the recessed low voltage mounting assembly of  FIG. 1 . 
         FIG. 4  is a back view of the recessed low voltage mounting assembly of  FIG. 1 . 
         FIG. 5  is a front perspective view of the trim plate portion of the recessed low voltage mounting assembly of  FIG. 1 . 
         FIG. 6  is a rear perspective view of the trim plate depicted in  FIG. 5 . 
         FIG. 7  is a rear exploded perspective view of the recessed low voltage mounting of the present invention. 
         FIG. 8  is a front perspective view of the recessed low voltage mounting assembly of  FIG. 1  after the trim plate has been secured to the low voltage bracket. 
         FIG. 9  is a rear perspective view of the recessed low voltage mounting assembly of  FIG. 8 . 
         FIG. 10  is a front exploded perspective view of a one-piece embodiment of the recessed low voltage mounting assembly of the present invention. 
         FIG. 11  is a rear perspective view of the one-piece recessed low voltage mounting assembly of  FIG. 10 . 
     
    
    
     TABLE OF NOMENCLATURE 
     The following is a listing of part numbers used in the drawings along with a brief description: 
     
       
         
               
             
               
               
             
           
               
                   
               
               
                 Part Number Description 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 20 
                 recessed low voltage mounting assembly 
               
               
                 22 
                 low voltage mounting bracket 
               
               
                 24 
                 trim plate 
               
               
                 26 
                 low voltage component 
               
               
                 28 
                 long sidewall 
               
               
                 30 
                 short sidewall 
               
               
                 32 
                 enclosure 
               
               
                 34 
                 lateral peripheral wall 
               
               
                 35 
                 front face of lateral peripheral wall 
               
               
                 36 
                 front edge of sidewalls 
               
               
                 38 
                 longitudinal wall 
               
               
                 40 
                 rear opening 
               
               
                 42 
                 low voltage boss 
               
               
                 44 
                 wide flange 
               
               
                 46 
                 threaded bore in wide flange 
               
               
                 47 
                 aperture in wide flange 
               
               
                 48 
                 double-walled extension 
               
               
                 50 
                 opening 
               
               
                 52 
                 short lateral wall 
               
               
                 54 
                 aperture in short lateral wall 
               
               
                 56 
                 captive fastener 
               
               
                 58 
                 longitudinal brace 
               
               
                 60 
                 rear edge of longitudinal wall 
               
               
                 62 
                 lateral flange 
               
               
                 64 
                 rearward extending peripheral flange 
               
               
                 66 
                 short side of trim plate 
               
               
                 68 
                 long side of trim plate 
               
               
                 70 
                 first aperture 
               
               
                 72 
                 second aperture 
               
               
                 74 
                 countersunk area 
               
               
                 76 
                 trim plate fastener 
               
               
                 77 
                 fastening arrangement 
               
               
                 78 
                 flag adjustment screw 
               
               
                 80 
                 head of flag adjustment screw 
               
               
                 82 
                 bore in flag 
               
               
                 84 
                 flag 
               
               
                 86 
                 flat face 
               
               
                 87 
                 mounting arrangement 
               
               
                 88 
                 fastener for low voltage component 
               
               
                 90 
                 bore in low voltage boss 
               
               
                 92 
                 brace member 
               
               
                 94 
                 groove 
               
               
                 96 
                 flag in counterclockwise position 
               
               
                 98 
                 flag in clockwise position 
               
               
                 100 
                 alignment tab 
               
               
                 102 
                 recessed area 
               
               
                 104 
                 wall 
               
               
                 106 
                 stud 
               
               
                 107 
                 second mounting arrangement 
               
               
                 108 
                 drywall 
               
               
                 110 
                 rear face of lateral flange 
               
               
                 200 
                 recessed low voltage mounting assembly 
               
               
                 202 
                 low voltage mounting bracket 
               
               
                 204 
                 trim plate 
               
               
                 205 
                 threaded portion of flag adjustment screw 
               
               
                 206 
                 mounting arrangement 
               
               
                 208 
                 thick wall portion 
               
               
                 210 
                 aperture 
               
               
                 212 
                 corner brace 
               
               
                 214 
                 sidewall edges 
               
               
                 216 
                 horizontal brace 
               
               
                 218 
                 rear edge of short sidewall 
               
               
                 220 
                 vertical brace 
               
               
                 Dl 
                 distance tab will offset mounting bracket from stud 
               
               
                 θ 1   
                 angle of fastener with respect to front edge of sidewall 
               
               
                   
               
             
          
         
       
     
     DETAILED DESCRIPTION OF THE INVENTION 
     With reference to  FIG. 1 , the present invention comprises a recessed low voltage mounting assembly  20  for securing a low voltage component on a wall. A first and preferred embodiment of the recessed mounting assembly  20  includes a low voltage mounting bracket  22  and a trim plate  24 . The recessed low voltage mounting assembly  20  enables the recessed mounting of a low voltage component  26 , such as the coaxial connector depicted in  FIG. 1 , on either a new wall under construction or on an existing wall. 
     The low voltage mounting bracket  22  includes long sidewalls  28  and short sidewalls  30  that define a low voltage enclosure  32  therein. A lateral peripheral wall  34  having a front face  35  is provided offset at a distance from the front edge  36  of the side walls  28  and  30  and extends into the enclosure  32 . A longitudinal wall  38  extends rearward from the lateral peripheral wall  34  and frames a rear opening  40 . Low voltage bosses  42  extend into the enclosure  32  from opposite sides of the longitudinal wall  38 . 
     A wide flange  44  extends outward along the front edge  36  of the short sidewalls  30  and includes a threaded bore  46  and an aperture  48  therein. Beyond the aperture along the short sidewalls  30  a double-walled extension  48  includes an opening  50  therein. A short lateral wall  52  extends between the two walls of the double-walled extension  48  and includes an aperture  54  therein. A captive fastener  56  extends from and is held therein in the aperture  54 . The short lateral wall  52  is at an angle with respect to the front edge  36  of the sidewalls  30  and thereby positions the captive fasteners  56  at an angle θ 1  with respect to the front edge  36 . Preferably the captive fasteners  56  are at an angle θ 1  of between 40 and 50 degrees with respect to the front edge of said sidewalls  28  and  30 . A longitudinal brace  58  extends rearward longitudinally from the rear of the wide flange  44  to the rear edge  60  of the longitudinal wall  38 . 
     The trim plate  24  includes a lateral flange  62  and a rearward extending peripheral flange  64 . The trim plate  24  includes opposing short sides  66  and opposing long sides  68 . Each side of the opposing short sides  66  includes a first aperture  70  and second aperture  72  therein. The rearward extending peripheral flange  64  of the trim plate  24  is of a slightly smaller size than the enclosure  32  defined by the inner surfaces of the long  28  and short sidewalls  30  and the trim plate  24  therefore aligns with and nests within the low voltage mounting bracket  22  when it is pressed therein. The first apertures  70  include countersunk areas  74  and accept trim plate fasteners  76  for securing the trim plate  24  to the low voltage mounting bracket  22 . The trim plate fasteners  76  provide a fastening arrangement  77  for securing the trim plate  24  to the low voltage mounting bracket  22 . Flag adjustment screws  78  include heads  80  that extend through the second apertures  72 . The second apertures  72  are of a diameter larger than the diameter of the heads  80  of the flag adjustment screws  78  thereby allowing the flag adjustment screws  78  to turn freely in the second apertures  72  even after the trim plate  24  is secured to the low voltage mounting bracket  22 . The flag adjustment screws  78  are threaded through bores  82  in flags  84 . Each flag  84  includes a flat face  86  thereon that is parallel with the front edge  36  of the low voltage bracket  22 . The flag adjustment screws  78  and flags  84  form a mounting arrangement  87  for mounting the low voltage mounting assembly to a wall. The mounting arrangement  87  includes rotatable flags  84  that may be rotated to draw the flags  84  toward the trim plate  24  for securing the recessed low voltage mounting assembly  20  to a wall (not shown). Alternatively, the low voltage mounting bracket  22  may be secured to a stud (not shown) with captive fasteners  56  and the trim plate  24  then secured to the bracket  22  to provide a finished mounting assembly  20  on a wall. A low voltage component  26  may then be secured by fasteners  88  to bores  90  in the low voltage bosses  42 . 
     Referring to the front view of the recessed low voltage mounting assembly  20  in  FIG. 2 , the bosses  42  extending from the longitudinal wall  38  include brace members  92  extending there between each boss  42  and the longitudinal wall  38  to brace and strengthen the bosses  42 . Grooves  94  are provided laterally along the face of each boss  42  to provide an open area for accommodating the edge of a low voltage component (not shown). The rotatable flags  84  are shown in  FIGS. 2 and 3  rotated fully clockwise by the flag adjustment screws  78 . 
     As shown in  FIG. 4 , the rotatable flags  84  can be rotated from a counterclockwise position  96  (in phantom lines), wherein the flags  84  are essentially flush against the short sidewalls  30 , to a clockwise position  98  (in solid lines) in which the flags  84  butt against the longitudinal brace  58  and are thereby essentially perpendicular with respect to the short sidewalls  30 . The longitudinal brace  58  thereby provides a stop for stopping the rotation of the rotatable flags  84  when they are rotated clockwise and stops the flags  84  when they are extended perpendicular to the sidewalls  30 . Alignment tabs  100  extend outwards from one long sidewall  28  of the low voltage mounting bracket  22  to provide an alignment mechanism for aligning the low voltage mounting bracket  22  at a proper depth with respect to a stud (not shown) so that the front edge of the bracket  22  will align flush with the eventual face of the drywall when the bracket assembly  20  is used in new construction. 
     The trim plate  24 , as shown in  FIGS. 5 and 6 , includes the lateral flange  62 , the rearward extending peripheral flange  64 , opposing short sides  66 , and opposing long sides  68 . First apertures  70  extending through the lateral flange  62  include countersunk areas  74  and second apertures  72  are provided for later accommodating the flag adjustment screws. 
     As shown in  FIG. 7 , the trim plate  24  mates with the low voltage mounting bracket  22 . The rearward extending peripheral flange  64  of the trim plate  24  nests within the front opening of the low voltage mounting bracket  22  defined by the short sidewalls  30  and long sidewalls  28 . A recessed area  102  is defined by the longitudinal brace  58  and the wide flange  44  provides space for the flags (not shown) to nest when rotated counterclockwise or to the open position. Thus the flags will be positioned flush against the short sidewalls  30  and will not interfere with insertion of the box within a hole in a wall. 
     With reference to  FIG. 8  for the operation of the recessed low voltage mounting assembly  20  in an old work situation, the rotatable flags  84  are initially rotated counterclockwise or flush against the short sidewalls  30  of the low voltage mounting bracket  22 . The recessed low voltage mounting assembly  20  is then inserted into the existing hole in the wall  104 , a portion of which the wall  104  and the drywall  106  are shown. The flag adjustment screws  78  are then rotated clockwise and tightened until the assembly  20  is clamped to the wall  104  by the flat face  86  of the flags  84  and the lateral flange  62  pressing on opposing sides of the wall  104 . 
     With reference to  FIG. 1 , an alternative mode of operation of the recessed low voltage mounting assembly  20  is available if desired for new construction. In this case, the low voltage mounting bracket  22  is pressed flush against a stud  106  and the captive fasteners  56 , which provide a second mounting arrangement  107  for securing the low voltage mounting assembly  20  to a wall, are driven into the stud  106 . After the drywall  108  is secured to the face of the studs  106 , the trim plate  24  is then secured to the low voltage mounting bracket  22  with fasteners  76 . A low voltage component  26  can then be installed within the recessed enclosure  32 . 
     Referring to  FIG. 9 , the lateral flange  62  includes a rear face  110  for mounting flush against the wall  104 . By providing a recessed low voltage mounting assembly  20  with a trim plate  24  separate of the mounting bracket  22 , the bracket  22  need not be mounted exactly flush with the wall  104 . Even with the bracket  22  mounted somewhat behind the wall surface, such as with captive fastener  56  driven into stud  106 , securing the trim plate  24  to the bracket  22  will draw the rear face  110  of the lateral flange  62  flush against the wall  104  thereby creating an attractive recessed mounting assembly  20  for a low voltage component. The alignment tabs  100  provide a convenient means of offsetting the low voltage mounting bracket  22  the proper distance from the front of the stud  106 , a portion of which is shown in the figure, in a new construction situation to establish a proper offset when securing the bracket  22  to the stud  106  with the captive fasteners  56  and later installing the drywall  108  around the bracket  22 . The alignment tabs  100  include a length D 1  that establishes the proper offset for standard ½″ thick drywall  108 . Thus, pressing the bracket up against the stud  106  until the alignment tabs  100  make contact with the stud  106  establishes the proper position for the bracket  22 , at which point the captive fasteners  56  can be driven into the stud  106 . Although the captive fasteners  56  are depicted as screws in  FIG. 9 , they can also be nails. 
     The low voltage mounting bracket  22  and trim plate  24  portions of the recessed low voltage mounting assembly  20  of the present invention may be constructed of metal or plastic. In an especially preferred embodiment, the low voltage mounting bracket  22  and trim plate  24  are each molded separately in one piece of plastic. 
     With reference to  FIG. 10 , there is shown a second embodiment of the recessed low voltage mounting assembly  200 . The recessed low voltage mounting assembly  200  depicted in  FIG. 10  is a one-piece apparatus in which the low voltage mounting bracket  202  includes an integral trim plate  204 . The assembly  200  includes an aperture  72  in the trim plate  204  that accommodates the flag adjustment screws  78 . Flag adjustment screws  78  pass through apertures  72  and are secured into bores  82  in flags  84 . The flag adjustment screws  78  include a head portion  80  and a threaded portion  205  and form a mounting arrangement  206  for securing the recessed low voltage mounting assembly  200  to a wall  104 . Longitudinal braces  58  extend rearward from the trim plate  204  and provide a stop for locking the flags in proper position when they are rotated clockwise with respect to the front of the assembly  200 . A lateral peripheral wall  34  having a front face  35  is provided offset at a distance from the front edge  36  of the side walls  28  and  30  and extends into the enclosure  32 . The front face  35  of the lateral peripheral wall  34  provides a seat for accommodating a low voltage component (not shown) when the component is secured to the assembly  200 . 
     Referring to  FIG. 11 , the lateral flange  62  of the one-piece low voltage mounting assembly  200  includes a thick wall portion  208  with an aperture  210  therein for supporting the flag adjustment screw  78  as it passes there through the flange  62 . Aperture  210  is of a size larger than the threaded portion  205  of flag adjustment screw  78  to enable free rotation of the rotatable flags  84  within the lateral flange  62  of the trim plate  204 . The thick wall portion  208  provides additional support along the length of screw  78  to prevent it from wobbling or moving out of the desired axial rotation as it is turned to adjust the flag  84 . Four corner braces  212  are provided at the sidewall edges  214  where the long sidewalls  28  and short sidewalls  30  join and extend between the edge  214  and the lateral flange  62  to support the flange  62 . Brace members  92  are provided between each boss  42  and the longitudinal wall  38  to brace and strengthen the bosses  42 . A horizontal brace  216  extends along the rear edge  218  of the short sidewall  30  and joins the longitudinal brace  58  at one end. A vertical brace  220  extends from the opposite end of the horizontal brace  216  to the longitudinal wall  38  thereby bracing and strengthening the longitudinal wall  38  portion of the low voltage mounting assembly  200 . 
     With reference to  FIG. 10 , the one-piece low voltage mounting assembly  200  enables an installer to easily mount a low voltage device (not shown) recessed within a wall. The one-piece assembly  200  is ideal for recessing a low voltage device in an old work situation. The installer simply makes an appropriate sized hole to accommodate the sidewalls  28  and  30  of the low voltage bracket  202 , rotates the flags  84  counterclockwise so that they are flush against the short sidewalls  30 , and slides the low voltage bracket  202  into the hole until the trim plate  204  is flush against the wall  104 . The flag adjustment screws  78  are then rotated clockwise and tightened until the flat face  86  of the flags  84  are clamp the assembly  200  to the wall  104 . The flags  84  and trim plate  204  will clamp the low voltage assembly  200  to the wall  104 . 
     The advantage provided by the one-piece low voltage mounting assembly  200  is ease of manufacture. The main portion of the one piece low voltage mounting assembly  200 , including the low voltage bracket  202  and integral trim plate  204 , are molded in one piece of plastic thereby enabling low unit production cost. The completed low voltage mounting assembly  200  includes the flag adjustment screws  78  and flags  84 , with the flag adjustment screws  78  threaded partially into the bores  82  of the flags  84 . The flag adjustment screws  78  and flags  84  form a mounting arrangement  206  for mounting the low voltage mounting assembly to a wall. The mounting arrangement  206  includes rotatable flags  84  that may be rotated to draw the flags  84  toward the trim plate  204  for securing the recessed low voltage mounting assembly  200  to the wall  104 . 
     Having thus described the invention with reference to a preferred embodiment, it is to be understood that the invention is not so limited by the description herein but is defined as follows by the appended claims.