Patent Document

[0001]    This application is a Continuation-In-Part of U.S. patent application Ser. No. 12/384,467, filed on Apr. 3, 2009 entitled “Duplex Electrical Connector with One-Piece Connector Body”. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates to electrical box assemblies for mounting components for high and low voltage devices and specifically to an electrical device mounting assembly that can be quickly and easily installed on an interior wall of a building and provide high and low voltage components connections to a television, computer, home stereo system, intercom, security system controller, or other electrical device that requires both high and low voltage connections. 
       BACKGROUND OF THE INVENTION 
       [0003]    With the proliferation of flat panel televisions and various auxiliary devices, such as digital videodisc players, game stations, and surround sound systems, there is a need to manage the connections between these devices to ensure there is adequate power and also to manage the myriad cables and cords that accompany such systems. 
         [0004]    Conventional electrical boxes have proven inadequate for these devices as they mount the high and low voltage connections for these components flush with the wall, which makes the plugs or connectors that mate with the wall-mounted components protrude from the wall thereby making it difficult to mount an electrical device such as a television close to the wall. Electrical plugs or cords that extend from the wall are also susceptible to damage, such as from vacuum cleaners or other household hazards which may brush against the plugs or cords. 
         [0005]    What is needed therefore is an electrical device mounting assembly that provides connection points for both high and low voltage components, provides isolation of high voltage connections from low voltage connections, provides features for managing the plethora of cables and wiring associated with modern television systems, and recesses the end connector of cords or cables to protect the plug ends of cords or end connectors of cables from undesirable contact with household appliances or household occupants. Furthermore, for electrical mounting assemblies that recess the ends of electrical cords within the wall, it is desirable to minimize the depth of the mounting assemblies to minimize the size and cost of manufacturing such assemblies and also to enable the mounting assemblies to fit within substantially narrow wall cavities. What is also needed is an electrical device mounting assembly that is configurable by the installer to meet the needs of the particular electrical device that it is used with. 
         [0006]    Parent U.S. patent application Ser. No. 12/384,467, filed on Apr. 3, 2009, which has been incorporated herein by reference, disclosed an electrical device mounting assembly that was capable of accepting two electrical component mounting devices, which could be two high voltage mounting devices, two low voltage mounting devices, or one of each. The mounting assembly included an arrangement for direct mounting to wall studs. 
         [0007]    The current invention provides a one-gang electrical device mounting assembly that includes ports for entry of low voltage cables and an angled mounting surface for connection of an electrical component mounting device at the opposing end. The electrical device mounting assembly is especially adapted for use with the newer small LCD flat panel televisions, which typically require a power connection at one end and audiovisual (AV) inputs at the opposite end. Thus the electrical device mounting assembly of the present invention enables an installer to configure the assembly to provide power at one end and AV connections, such as HDMI cables at the opposite end. The electrical device mounting assembly recesses all such power and signal hookups within the assembly, thereby enabling mounting of the flat panel television flush against the wall. The mounting assembly includes rotatable clamp arms to facilitate rapid connection to the drywall of a building. 
       SUMMARY OF THE INVENTION 
       [0008]    The invention is an electrical device mounting assembly that enables mounting of high and low voltage components in a single assembly for providing power and low voltage signals to a television or other electrical device that requires both high and low voltage connections. The electrical device mounting assembly provides mounting locations for recessing various electrical components behind the wall surface to make them unobtrusive and out of the way. The mounting assembly includes a mounting frame and a trim plate. One end of the mounting frame is adapted to mount either a high voltage electrical box or a low voltage mounting plate at an angle with respect to the wall, thereby minimizing the depth of the mounting frame while providing sufficient space for recessing plug ends of electrical cords and terminal ends of signal cables within the wall. A second end of the mounting frame includes open ports for passage of low voltage cables or wires there through. The low voltage mounting plates are capable of accepting standard jacks for broadband cable, direct TV, surround sound cabling, or phone systems. The electrical device mounting assembly enables easy consolidation of all the various power and signal hookups for TV or home entertainment systems in a single assembly that is recessed within the wall and allows flush mounting of a flat panel TV or similar electronic device directly over the mounting assembly. Rotatable clamp arms on the mounting frame facilitate rapid installation on the drywall of a building. 
       OBJECTS AND ADVANTAGES 
       [0009]    The electrical device mounting assembly of the present invention provides several advantages over the prior art, including:
       (1) The mounting assembly can be configured to provide all of the hookups for a flat panel TV or similar device, including power and low voltage wiring and cables.   (2) The mounting assembly includes a mounting surface that can be configured to accept a mounting device for an electrical component or plate, which mounting device can include either a high voltage box a low voltage frame.   (3) Mounting surfaces are at an angle with respect to the front of the electrical device mounting assembly thereby advantageously minimizing the depth of the mounting assembly and enabling its use in shallow wall cavities.   (4) The mounting assembly recesses electrical components and the plug ends of cords or end connectors of cables within the wall surface to render them unobtrusive and out of the way.   (5) Recessing the electrical components within the wall enables flush mounting the recipient electrical device, such as a television, against the wall.   (6) The mounting assembly includes rotatable clamp arms to enable an installer to rapidly prepare the wall and flush mount the assembly to a wall.   (7) The mounting assembly is a one-gang box that is ideal for supplying power and AV signals to the latest small LCD TVs, which typically have power at one corner and AV inputs at the other corner. One side of the mounting assembly is for low voltage and the opposite side is for power.   (8) The electrical device mounting assembly provides features for managing the plethora of cables and wiring associated with modern television systems thereby providing a clean installation that is unobtrusive and minimizes the amount of wires and cables running between the wall and the television, speaker system, or other components of a home entertainment system.       
 
         [0018]    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 
         [0019]      FIG. 1  is an exploded perspective view of a first embodiment of an electrical device mounting assembly according to the present invention. 
           [0020]      FIG. 2  is a front view of a mounting frame that forms a portion of the electrical device mounting assembly of  FIG. 1 . 
           [0021]      FIG. 3  is a side view of the mounting frame as viewed from the top side of  FIG. 2 . 
           [0022]      FIG. 4  is a sectional view of the mounting frame taken along line  4 - 4  of  FIG. 2 . 
           [0023]      FIG. 5  is a sectional view of the mounting frame taken along line  5 - 5  of  FIG. 2 . 
           [0024]      FIG. 6  is a perspective view of a low voltage plate that forms a portion of the electrical device mounting assembly of  FIG. 1 . 
           [0025]      FIG. 7  is a side view of the low voltage plate of  FIG. 6 . 
           [0026]      FIG. 8  is an end view of the low voltage plate of  FIG. 6 . 
           [0027]      FIG. 9  is a perspective view of a high voltage box that forms a portion of the electrical device mounting assembly of  FIG. 1 . 
           [0028]      FIG. 10  is a side view of the high voltage box of  FIG. 9 . 
           [0029]      FIG. 11  is an end view of the high voltage box as viewed from the bottom of  FIG. 9 . 
           [0030]      FIG. 12  is an exploded perspective view of the electrical device mounting assembly of the present invention including a high voltage component mounted in the high voltage box and two low voltage components mounted in the low voltage plate. 
           [0031]      FIG. 13  is a perspective view of the electrical device mounting assembly of the present invention mounted to a wall and with a high voltage component and two low voltage components mounted therein. 
           [0032]      FIG. 14  is a perspective view of a second embodiment of an electrical device mounting assembly according to the present invention mounted to a wall. 
           [0033]      FIG. 15  is an exploded perspective view of a third and preferred embodiment of an electrical device mounting assembly according to the present invention. 
           [0034]      FIG. 16  is a front perspective view of a mounting frame that forms a portion of the electrical device mounting assembly of  FIG. 15 . 
           [0035]    Fig. is a front perspective view of the mounting frame of  FIG. 16 . 
           [0036]      FIG. 18  is a front elevation view of the mounting frame of  FIG. 16 . 
           [0037]      FIG. 19  is a sectional view of the mounting frame taken along line  19 - 19  of  FIG. 18 . 
           [0038]      FIG. 20  is a front perspective view of a trim plate that forms a portion of the electrical device mounting assembly of  FIG. 15 . 
           [0039]      FIG. 21  is a rear perspective view of the trim plate of  FIG. 20 . 
           [0040]      FIG. 22  is a front elevation view of the electrical device mounting assembly of  FIG. 15 . 
           [0041]      FIG. 23  is a sectional view of the electrical device mounting assembly taken along line  23 - 23  of  FIG. 22 . 
           [0042]      FIG. 24  is a perspective view of the preferred embodiment of the electrical device mounting assembly secured to a wall with a duplex receptacle installed therein and the trim plate secured to the mounting frame. 
           [0000]    
         
           
                 
               
                 
                 
               
                 
                 
               
             
                 
                     
                 
                 
                   Table of Nomenclature 
                 
                 
                   The following is a listing of part numbers used in 
                 
                 
                   the drawings along with a brief description: 
                 
               
            
             
                 
                   Part Number 
                   Description 
                 
                 
                     
                 
               
            
             
                 
                   20 
                   electrical device mounting assembly, first embodiment 
                 
                 
                   22 
                   mounting frame 
                 
                 
                   24 
                   low voltage mounting plate 
                 
                 
                   26 
                   high voltage box or power box 
                 
                 
                   28 
                   trim plate 
                 
                 
                   30 
                   side wall 
                 
                 
                   32 
                   end wall 
                 
                 
                   34 
                   back wall 
                 
                 
                   35 
                   corner wall 
                 
                 
                   36 
                   aperture or bore in back wall 
                 
                 
                   38 
                   open area 
                 
                 
                   40 
                   tab 
                 
                 
                   42 
                   cable opening 
                 
                 
                   44 
                   boss 
                 
                 
                   46 
                   front face of mounting frame 
                 
                 
                   48 
                   spacer 
                 
                 
                   50 
                   front face of spacer 
                 
                 
                   52 
                   slot 
                 
                 
                   54 
                   gap 
                 
                 
                   56 
                   enclosure of mounting frame 
                 
                 
                   58 
                   brace 
                 
                 
                   60 
                   second brace 
                 
                 
                   62 
                   raised area 
                 
                 
                   64 
                   first frame 
                 
                 
                   66 
                   second frame 
                 
                 
                   68 
                   corner wall of frame 
                 
                 
                   70 
                   first lip 
                 
                 
                   72 
                   mounting boss or arm 
                 
                 
                   73 
                   mounting bore 
                 
                 
                   74 
                   second lip 
                 
                 
                   75 
                   frame opening 
                 
                 
                   76 
                   component connection point 
                 
                 
                   78 
                   component bore 
                 
                 
                   79 
                   component boss 
                 
                 
                   80 
                   back side of low voltage plate 
                 
                 
                   82 
                   filet 
                 
                 
                   84 
                   sidewall of electrical box 
                 
                 
                   86 
                   end wall of electrical box 
                 
                 
                   88 
                   electrical box enclosure 
                 
                 
                   90 
                   recessed area 
                 
                 
                   92 
                   knockout 
                 
                 
                   94 
                   stud 
                 
                 
                   96 
                   fastener 
                 
                 
                   98 
                   fastener 
                 
                 
                   99 
                   attachment arrangement 
                 
                 
                   100 
                   duplex receptacle 
                 
                 
                   102 
                   CATV connector plate 
                 
                 
                   104 
                   end flange 
                 
                 
                   106 
                   inner aperture 
                 
                 
                   108 
                   outer aperture 
                 
                 
                   110 
                   fastener 
                 
                 
                   112 
                   bore 
                 
                 
                   114 
                   opening in trim plate 
                 
                 
                   116 
                   mounting fastener 
                 
                 
                   120 
                   electrical device mounting assembly, second embodiment 
                 
                 
                   122 
                   trim plate 
                 
                 
                   124 
                   first end flange 
                 
                 
                   126 
                   second end flange 
                 
                 
                   130 
                   fastener 
                 
                 
                   132 
                   end of trim plate 
                 
                 
                   134 
                   electrical fitting or connector 
                 
                 
                   200 
                   electrical device mounting assembly, preferred embodiment 
                 
                 
                   202 
                   mounting frame 
                 
                 
                   204 
                   first end of mounting frame 
                 
                 
                   206 
                   port 
                 
                 
                   208 
                   second end of mounting frame 
                 
                 
                   210 
                   trim plate 
                 
                 
                   212 
                   flange 
                 
                 
                   214 
                   open area 
                 
                 
                   216 
                   V-shaped ledge 
                 
                 
                   218 
                   support arm 
                 
                 
                   220 
                   lip 
                 
                 
                   222 
                   strut 
                 
                 
                   224 
                   inner aperture in flange of mounting frame 
                 
                 
                   226 
                   outer aperture in flange of mounting frame 
                 
                 
                   228 
                   U-shaped ridge 
                 
                 
                   230 
                   frame 
                 
                 
                   232 
                   front side of frame 
                 
                 
                   234 
                   rear side of frame 
                 
                 
                   235 
                   central opening 
                 
                 
                   236 
                   peripheral wall 
                 
                 
                   238 
                   inner periphery 
                 
                 
                   240 
                   truncated corner 
                 
                 
                   242 
                   inner aperture in trim plate 
                 
                 
                   244 
                   outer aperture in trim plate 
                 
                 
                   247 
                   mounting arrangement 
                 
                 
                   248 
                   rotatable clamp arm 
                 
                 
                   249 
                   alignment arrangement for mounting device 
                 
                 
                   250 
                   mounting fastener 
                 
                 
                   251 
                   oversize aperture in flange 
                 
                 
                   252 
                   plate fastener 
                 
                 
                   253 
                   attachment arrangement 
                 
                 
                   254 
                   box fastener 
                 
                 
                   256 
                   wall 
                 
                 
                   258 
                   duplex receptacle 
                 
                 
                   260 
                   drywall 
                 
                 
                   Θ1 
                   angle of first brace with respect to front face 
                 
                 
                   Θ2 
                   angle of second brace with respect to front face 
                 
                 
                   Θ3 
                   angle of first frame with respect to second frame 
                 
                 
                   Θ4 
                   angle of first lip with respect to first frame 
                 
                 
                   Θ5 
                   angle of second lip with respect to second frame 
                 
                 
                   D1 
                   depth of mounting frame 
                 
                 
                   D2 
                   spacing between apertures in trim plate 
                 
                 
                     
                 
               
            
           
         
       
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0043]    With reference to  FIG. 1  there is shown a first embodiment of an electrical device mounting assembly  20  according to the present invention. The electrical device mounting assembly  20  includes a mounting frame  22 , two mounting devices including a low voltage mounting plate  24  and a high voltage box  26 , and a trim plate  28 . 
         [0044]    Referring to  FIGS. 2-5 , the mounting frame  22  has walls  30  and  32  including two side walls  30  and two end walls  32 , a back wall  34  extending over a portion of the rear of the mounting frame  22  at its center and two corner walls  35 . Several apertures  36  are provided in the back wall  34 . Two large open areas  38  are provided on either side of the partial back wall  34  and a plurality of tabs  40  are provided on the mounting frame  22  extending inward from the end walls  32 . The side walls  30  include cable openings  42  therein and the back wall  34  includes bosses  44  that are coincident with the apertures  36  in the back wall. The side walls  30  and end walls  32  of the mounting frame  22  terminate in a planar front face  46 . Integral spacers  48  extend outwards from the end walls  32  and each include a flat front face  50  that is planar with the front face  46  of the mounting frame  22 . The integral spacers  48  are preferably ½-inch in length and thereby enable an installer to rapidly and accurately orient the mounting frame  22  with respect to a stud (not shown) in a new work situation in order to properly allow the proper spacing for applying conventional ½-inch drywall over the stud. A plurality of slots  52  are provided in the side walls  30  and end walls  32  of the mounting frame  22 . The tabs  40  are offset from the corner walls  35  thereby creating a gap  54  there between. As shown in  FIG. 4 , the mounting frame  22  includes an enclosure  56  defined by the side walls  30  and end walls  32  and a plurality of braces  58  and second braces  60  extending from each of the side walls  30  into the enclosure  56 . Each brace  58  is at an angle of Θ 1  with respect to the front face  46  and each second brace  60  is at an angle of Θ 2  with respect to the front face  46 . As will be described herein, it is critical to the present invention that the braces  58  and second braces  60  are each at an angle with respect to the front face  46  of the mounting frame  22  as this will insure that multiple component housings (not shown) can be mounted within the mounting frame  22  while minimizing the depth of the mounting frame  22  with the depth of the mounting frame  22  being defined as the distance between the front face  46  and the back wall  34  and shown as distance D 1  in  FIG. 5 . Most preferably, the depth D 1  of the mounting frame  22  according to the present invention is 3.8-inches or less, which depth is kept to a minimum by orienting the mounting devices  24  and  26  at an angle with respect to the front face  46  of the mounting frame  22 . Thus, the mounting of the mounting devices  24  and  26  at the desired angle achieves the unexpected results of enabling the fitting of a substantial number of mounting devices  24  and  26  in a mounting assembly  20  that extends a relatively short distance into the wall while still providing space for recessing the installed electrical components and any connected electrical cord plugs. As shown in  FIG. 4 , the braces  58  and  60  are formed by substantially triangular-shaped raised areas  62  in the side walls  30  of the mounting frame  22 . The raised areas  62  extend from both the top and bottom side walls  30  and provide the bracing surfaces  58  and  60  thereon. 
         [0045]    With reference to  FIGS. 6-8  there is shown a low voltage mounting plate  24  that may form a portion of an electrical device mounting assembly according to the present invention. The low voltage mounting plate  24  includes a first frame  64  and a second frame  66  integral with one another at a corner wall  68 . The frames  64  and  66  are at an angle Θ 3  with respect to one another, which angle is preferably between 60 and 120 degrees and more preferably is 90 degrees, as depicted in  FIG. 8 . A first lip  70  extends at an angle Θ 4  from the first frame  64  and two mounting bosses  72  having mounting bores  73  therein extend from the first lip  70 . The second frame  66  also includes a second lip  74  extending there from with the second lip  74  extending at an angle Θ 5  from the second frame  66 . When the angle Θ 3  of the first frame  64  with respect to the second frame  66  is 90 degrees, the angle Θ 4  of the first lip  70  with respect to the first frame  64  is preferably 60 degrees and the angle Θ 5  of the second lip  74  with respect to the second frame  66  is preferably 30 degrees. The frames include frame openings  75  therein. Component connection points  76  extend into the frame openings  75  and include component bores  78  therein. The component connection points  76  include component bosses  79  extending from the back side  80  of the low voltage mounting plate  24 . A filet  82  is provided on the back side  80  of the low voltage mounting plate  24  extending between the frames  64  and  66 . When the low voltage mounting plate  24  is molded of plastic, the filet  82  is molded integrally with the low voltage mounting plate  24  and adds strength to the plate  24  at the point where the two frames  64  and  66  meet. 
         [0046]    Referring to  FIGS. 9-11 , the high voltage box  26  includes many elements in common with the low voltage frame including a first frame  64 , second frame  66 , first lip  70 , second lip  74 , mounting bosses  72 , and component connection points  76 . The high voltage box  26  also includes a sidewall  84  and end walls  86  that cooperate with the second frame  66  to provide an electrical box enclosure  88  for accepting a high voltage electrical component (not shown) therein. A recessed area  90  is provided in each end wall  86  with a knockout  92  provided in each recessed area. 
         [0047]    Reference is made to  FIG. 12  for an explanation of the operation of the electrical device mounting assembly  20  of the present invention. The electrical device mounting assembly  20  can be mounted to a wall and configured to hold two high voltage electrical boxes  26 , two low voltage mounting plates  24 , or one high voltage electrical box and one low voltage mounting plate. Thus, the electrical device mounting assembly can be configured to provide the proper amount of high and low voltage connection points depending on the needs of the situation. The particular arrangement depicted in  FIG. 12  depicts the electrical device mounting assembly  20  being configured to hold one high voltage electrical box  26  and one low voltage mounting plate  24 . The electrical device mounting assembly can be used for either new work, where sheetrock has not been installed over the studs, or old work situations. For an old work installation, a portion of the existing sheetrock is removed, typically between two studs, in the location where electrical services are required. One end of the electrical device mounting assembly  20  is typically secured to a stud  94  with fasteners  96  as shown. 
         [0048]    After the electrical device mounting assembly  20  is secured at one end to the stud  94 , the assembly may be configured with two low voltage plates, two high voltage boxes, or one of each as desired. The high voltage box  26  and low voltage plate  24  can be installed into the electrical device mounting assembly  20  in any order by sliding the second lip  74  of the second frame  66  into the gaps  54  between the tabs  40  and corner wall  68 . The tabs  40  perform a critical function for the electrical device mounting assembly  20  as they enable an installer to rapidly configure the box with mounting devices  24  and  26 . The tabs  40  enable the mounting device  24  or  26  to easily seat in its proper place in the box assembly  20  as the tabs  40  enable the second lip  74  of the mounting device to slide into the gaps  54  formed by the tabs. Brace  58  and second brace  60  of mounting frame  22  brace and support the first frame  64  and second frame  66  respectively of the low voltage mounting plate  24  and high voltage box  26  when they are inserted into the mounting frame  22  and position the frames  64  and  66  at the desired angle with respect to the front face  46  of the mounting frame  22 . The mounting devices  24  and  26  are then secured to the mounting frame  22  by driving fasteners  98  through bosses  72  of mounting devices  24  and  26  into apertures  36  in the back wall  34  of mounting frame  22 . Fasteners  98  and bosses  72  therefore form an attachment arrangement  99  for securing the mounting devices  24  and  26  within the enclosure  56  of the mounting frame  22 . In  FIG. 12 , the high voltage box  26  is depicted with a duplex receptacle  100  installed therein and low voltage mounting plate  24  is depicted with two CATV connector plates  102  installed therein. The installation is completed by securing trim plate to the mounting frame  22 . Trim plate  28  includes two end flanges  104  with inner apertures  106  and outer apertures  108  therein. After the mounting frame  22  has been configured, fasteners  110  are driven into bores  112  in each corner of the front face  46  of the mounting frame  22 . The high and low voltage electrical components  100  and  102  will then be accessible through the opening  114  in trim plate  28 . After the trim plate  28  is secured to the mounting frame  22 , mounting fasteners  116  may be driven through the end flange  104  opposite the stud  94  to secure the opposing end of the electrical device mounting assembly  20  to the wall. 
         [0049]    The completed electrical device mounting assembly  20  is depicted in  FIG. 13 . A low voltage mounting plate  24  has been installed in the right side of the assembly and a high voltage box  26  has been installed in the left side of the assembly. If an alternative arrangement of high and low voltage components is desired, the electrical device mounting assembly  20  may be configured with two high voltage boxes or with two low voltage mounting plates in lieu of one of each type electrical mounting device. 
         [0050]    With reference to  FIG. 14  there is shown a second embodiment of an electrical device mounting assembly  120 . Mounting assembly  120  includes a mounting frame  22 , low voltage mounting plate  24 , and high voltage box  26  similar to the first embodiment. Mounting assembly  120  however includes a trim plate  122  in which the end flanges are nonsymmetrical including a first end flange  124  and a second end flange  126 . As shown in  FIG. 14 , the second end flange  126  is wider than the first end flange  124 . Trim plate  122  is sized to provide spacing equal to the standard spacing between studs. The spacing, denoted by D 2  in  FIG. 14 , is preferably  16 -inches between the outer apertures  108  in the end flanges  124  and  126  to match the conventional center-to-center spacing between adjacent studs. The distance between sidewall  30  of mounting frame  22  and the outer aperture  108  of first end flange  124  is approximately half the width of a conventional stud  94 . Thus the mounting frame  22  can be jammed against a stud  94  and secured thereto with fasteners  130  driven through slots  52  in sidewall  30  into stud  94 . After the low voltage mounting plate  24  and high voltage box  26  are installed in the mounting frame  22 , trim plate  122  is secured to the mounting frame  22  by fasteners  110 . The opposite end  132  of the trim plate  122  is then secured to the opposite stud  94  with fasteners  116 . The second embodiment of the trim plate  122  according to the present invention therefore provides the ability to anchor the electrical device mounting assembly  120  to a stud  94  at both ends of the assembly, thereby providing an electrical device mounting assembly  120  that is secured at both ends to the wall. 
         [0051]    As shown in  FIG. 11 , the high voltage box  26  may include a knockout or removable wall portion  92  therein in the recessed area  90  in one of the end walls  86 . The recessed area  90  in the sidewall  86  enables the use of electrical fittings or connectors such as the Black Button™ push-in fitting or connector  134  for connecting non-metallic cable to electrical boxes, which connector  134  is available from Arlington Industries of Scranton, Pa. The recessed area  90  permits use of the connectors  134  while preventing the connectors from projecting beyond the sidewall  86  and interfering with placement of the electrical device mounting assembly  20  in locations where space is tightly restricted. 
         [0052]    With reference to  FIG. 15  there is shown a third and preferred embodiment of an electrical device mounting assembly  200  according to the present invention. In the figures that depict assembly  200 , the same reference numerals will be used to denote any elements that are in common with those of the first embodiment. The preferred embodiment of the electrical device mounting assembly  200  includes a mounting frame  202  with a brace  58  extending from the sidewall  30  toward a first end  204  of the mounting frame  202 , large ports  206  for entry of low voltage cables (not shown) at the second end  208  of the mounting frame  202 , and a trim plate  210  that is secured to an elongated flange  212  that extends from the sidewalls  30  of the mounting frame  202 . The brace  58  can be configured to accept an electrical component mounting device, which, depending on the user&#39;s preference, can be either a low voltage mounting plate  24  (see  FIGS. 6-8 ) or a high voltage box  26  (see  FIGS. 9-11 ). The mounting frame  202  in  FIG. 15  is depicted as being configured with a high voltage box  26 . 
         [0053]    Referring to  FIGS. 16 and 17 , the mounting frame  202  of the preferred embodiment of the mounting assembly includes sidewalls  30 , end walls  32 , and a back wall  34  defining an enclosure  56  therein. One large open area  214  is provided in the back wall  34 . One or more tabs  40  are provided on the corner wall  35  at the edge of the open area  214 . A substantially V-shaped ledge  216  extends into the enclosure  56  from the sidewalls  30  at the periphery of the open area  214 . The back wall  34  includes bosses  44  that are coincident with apertures  36  in the back wall and a plurality of slots  52  are provided in one end wall  32  of the mounting frame  202 . To add rigidity between the flanges  212  and the walls of the mounting frame  202 , there are provided a plurality of support arms  218  integral with and extending outward from the sidewalls  30 . The flanges  212  include a rearward-extending lip  220  and a plurality of struts  222  extending between the lips  220  and the sidewalls  30 . 
         [0054]    With reference to  FIGS. 18 and 19 , one end wall  32  of the mounting frame  202  includes integral spacers  48  extending outward from the end wall  32  and each include a flat front face  50  that is planar with the front face  46  of the mounting frame  202 . The integral spacers  48  are preferably ½-inch in length and thereby enable an installer to rapidly and accurately orient the mounting frame  202  with respect to a stud (not shown) in a new work situation in order to allot the proper spacing for applying conventional ½-inch drywall over the stud. The flanges  212  include inner apertures  224  and outer apertures  226  therein. U-shaped ridges  228  extend from the back wall  34  adjacent to the apertures  36  in the back wall. 
         [0055]    Referring to  FIGS. 20 and 21 , the trim plate  210  includes a frame  230  having a front side  232  and a rear side  234  with a central opening  235 , and a peripheral wall  236  extending from the rear side  234  of the frame  230  around the inner periphery  238 . The peripheral wall  236  includes truncated corners  240 . The frame  230  portion of the trim plate  210  includes inner apertures  242  and outer apertures  244 . The peripheral wall  236  is slightly smaller than the side walls  30  and end walls  32  in the mounting frame (see  FIG. 15 ) and thus will nest within the opening formed by the side walls  30  and end walls  32  of the mounting frame  202 . 
         [0056]    As shown in  FIG. 15 , the electrical device mounting assembly  200  is used to provide electrical services to a flat panel TV or similar wall mounted electronic device. It has the advantages of recessing electrical components and all cables, wiring, and plug ends of cables within the wall. The electrical device mounting assembly  200  is an assembly of the mounting frame  202 , an electrical component mounting device such as a power box  26 , and the trim plate  210 . The mounting frame  202  includes a mounting arrangement  247  for securing the mounting frame to a wall with the mounting arrangement  247  including a plurality of rotatable clamp arms  248 . The rotatable clamp arms  248  are attached to the ends of mounting fasteners  250  that extend through oversize apertures  251  in the flanges  212  and are accessible from the front of the mounting frame. 
         [0057]    The electrical device mounting assembly  200  is operated by first cutting a hole in the drywall of a building. The hole (not shown) is cut of a size and shape to accommodate the outer periphery of the mounting frame  202 . A power box  26  is installed into the mounting frame  202  by sliding second lip  74  of power box  26  between tabs  40  and corner wall  35  of mounting frame  202  and rotating the power box  26  until the first frame  64  is flush against brace  58  and arms  72  of power box  26  nest within the U-shaped ridges  228  on the back wall  34  of the mounting frame  202 . The U-shaped ridges  228  serve as an alignment arrangement  249  (see  FIG. 22 ) for aligning the power box mounting device  26  with the aperture  36  in the back wall  34  of the mounting frame  202 . Box fasteners  254  are then driven through arms  72  into the bores  36  of bosses  44  (see  FIG. 23 ) to secure the power box  26  to the mounting frame  202 . The tabs  40  and bosses  44  on the mounting frame  202 , the arms  72  on the mounting device  26 , and the box fasteners  254  form an attachment arrangement  253  (see  FIG. 23 ) for securing the mounting device  26  to the mounting frame  202 . Electrical cables (not shown) are pulled into the power box  26  on one end of the mounting frame  202  through knockouts  92  and low voltage cables are pulled into the other end of the mounting frame  202  through one or more ports  206 . 
         [0058]    After power box  26  is secured to the mounting frame  202 , trim plate  210  is secured to the mounting frame  202  by driving plate fasteners  252  through the outer apertures  244  in the trim plate  210  into the outer apertures  226  in the flange  212  of the mounting frame  202 . With trim plate  210  secured to the mounting frame  202 , inner apertures  242  in trim plate  210  line up with the heads of the mounting fasteners  250  in the flange  212  of the mounting frame  202 . As inner apertures  242  in trim plate  210  are of larger diameter than the heads of the mounting fasteners  250 , the mounting fasteners  250  and attached clamp arms  248  can be rotated while the trim plate is secured to the mounting frame  202 . 
         [0059]    The mounting assembly  200  is then inserted into the hole until trim plate  210  is flush against the wall surface. Using a tool such as a screwdriver, the mounting fasteners  250  are then rotated clockwise until clamp arms  248  engage support arms  218  and thereafter with continued rotation are drawn toward flange  212  of mounting frame  202 . Mounting fasteners  250  are rotated until clamp arms  248  are securely drawn against the back of the drywall (not shown) surrounding the hole in the wall. Thus a major advantage of the preferred embodiment of the electrical device mounting assembly  200  is that the mounting assembly can be mounted substantially anywhere on the wall as attachment to wall studs is not required. An operator can simply find the desired place on the wall for locating an electrical device, such as a flat panel TV, and simply cut a hole in the drywall to accommodate the periphery of the mounting frame  202 . The length of the mounting frame  202  from end wall to end wall  32  is approximately 9-inches, enabling an installer to easily fit the mounting frame  202  anywhere between two studs. If stud anchoring is desired in addition to the clamp arms  248 , the first end  204  of mounting frame  200  can be positioned flush against a stud and fasteners (not shown) can be driven through slots  52  in end wall  32 . 
         [0060]    With reference to  FIGS. 22 and 23 , the preferred embodiment of the electrical device mounting assembly  200  is depicted with a power box  26  secured therein to the mounting frame  202 . The power box  26  is held to mounting frame  202  by tabs  40  on one end of the box and by box fasteners  254  secured through back wall  34  into bosses  44  integral with the back wall. Power box  26  includes connection points  76  for connection of a duplex receptacle (not shown) for providing power to the appliance it will be used in conjunction with. Audio visual or similar low voltage cables can be pulled into box through low voltage ports  206 . As shown in  FIG. 23 , any wires or cables within mounting frame  202  will be recessed well within the wall  256  as well as any plug ends of power cords (not shown). As shown in  FIG. 22 , U-shaped ridges  228  of mounting frame  202  advantageously provide a seat for the arms  72  of a mounting device  26  to nest therein, thereby assisting in rapidly positioning the mounting device in mounting frame  202  and aligning the arms  72  with the bores  36  (see  FIG. 18 ) in the back wall  34  of the mounting frame. 
         [0061]    With reference to  FIG. 24  there is shown the preferred embodiment of the electrical device mounting assembly  200  installed on a wall with an electrical box  26  and the trim plate  210  secured to the mounting frame  202 . All the required connections for a flat panel TV, including power, such as the duplex receptacle  258  shown, and AV cables, will be housed within the enclosure  56  of the mounting assembly  200 . The plug end of electrical cords and all AV cables (not shown) will advantageously be recessed within the enclosure  56 , thereby enabling a flat panel TV or similar electrical device to be mounted over the mounting assembly  200  and flush against the wall  256 . Mounting the duplex receptacle  258  at an angle with respect to the front face of the mounting assembly  200  provides substantial volume within the enclosure  56  for recessing any plug ends of electrical cords that will be plugged into the power receptacle. Substantial volume is also provided on the opposite end of the enclosure to accommodate any low voltage cables entering the enclosure  56  through low voltage ports  206 . The rotatable clamp arms  248  advantageously provide a means of rapidly mounting the assembly  200  to a wall  256  as all that is required is cutting a hole in the dry wall and tightening the clamp arms  248  against the drywall  260 . 
         [0062]    The various portions of the electrical device mounting assembly  200 , including the mounting frame  202 , low voltage mounting plate  24 , high voltage box  26 , and trim plate  210 , may be constructed of metal or plastic. Most preferably, the mounting frame  202 , low voltage mounting plate  24 , high voltage box  26 , and trim plate  210  are each molded in one piece of plastic. Suitable plastics include polycarbonate and polyvinylchloride. 
         [0063]    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.

Technology Category: 5