US20050109907A1

US20050109907A1 - Truncated round electrical fixture box

Info

Publication number: US20050109907A1
Application number: US10/891,665
Authority: US
Inventors: Greg Herth
Original assignee: Individual
Current assignee: Individual
Priority date: 2003-11-20
Filing date: 2004-07-15
Publication date: 2005-05-26
Also published as: CA2474524A1

Abstract

A modular interchangeable structural support ceiling fixture electrical housing box having a truncated cylindrical housing for mounting one or a plurality of electrical devices, such as ceiling lighting fixtures or smoke alarm devices. Each housing has at least one angled mounting bracket for fasteners, such as screws or nails, for attaching the housing box to a residential ceiling stud so as to permit interchangeable positioning within the housing. The box is interchangeable in that it can be used for either a new work box in new construction or for restoration.

Description

RELATED APPLICATIONS

This application is based upon provisional patent application No. 60/523,891 filed Nov. 20, 2003 and claims benefit under 35 USC § 119(e) thereof.

FIELD OF THE INVENTION

This invention relates to residential and commercial electrical wiring, and more particularly to modular structural support ceiling fixture electrical box for mounting ceiling lighting fixtures, wall lighting sconces or smoke/carbon monoxide alarm devices.

BACKGROUND OF THE INVENTION

Ceiling lighting fixtures are often mounted to a bracket across a box attached to a stud in the ceiling. These bracket mounts are less than stable for the ceiling lighting fixture, making loosening and/or falling of the fixture within the realm of possibility.
Existing electrical work boxes are described in U.S. Pat. No. 4,424,406 of Slater and U.S. Pat. No. 4,436,952 of Lockwood.
Lockwood '952 describes a work box with a conventional accessory screw holding bracket protruding up from the surface of one of the walls of the work box. The protruding bracket interferes with the flush placement of the work box within a hole within a wall corresponding in shape to the exterior of the work box.
Slater '406 describes a work box in general but is silent about a mounting means for the work box.
An improvement in electrical work boxes is shown in Applicant's U.S. Pat. No. 5,600,093 of Herth and Davis, which describes an electrical work box for new work and old work, wherein a novel interior attachment is described for vertically attaching the electrical work box to a building stud via an angled screw mount within the electrical work box.
However, Herth and Davis '093 does not describe a round ceiling mounted box which can be mounted to a ceiling stud to firmly suspend a ceiling lighting fixture or smoke/carbon monoxide alarm device therefrom.

OBJECTS OF THE INVENTION

It is therefore an object of the present invention to provide a dual purpose structural support ceiling fixture electrical work box, which can be adapted for multiple uses in either new construction or existing building renovations.
It is another object of the present invention to provide a structural support ceiling fixture electrical work box with an internal fastener mounting bracket, for fasteners, such as screws or nails.
It is yet another object of the present invention to provide a work box with a screw mounting bracket, which does not protrude above the exterior silhouette shape of the work box.
It is yet an object of the present invention to provide a structural support for smoke/carbon monoxide devices for buildings.
A further object of the present invention is to provide structural support ceiling fixture electrical work box which is economical to manufacture, easy to mount and of sturdy construction.
Therefore, these objects and related objects are attained in a structural support ceiling fixture electrical work box having a structure for holding different ceiling lighting fixtures, wall sconces or smoke/carbon monoxide alarm devices.
In a preferred embodiment, the structural support ceiling fixture electrical work boxes are truncated cylinders formed with one or more internal fastener mounting brackets in a flat sector wall, for inserting fasteners, such as nails or screws, within ceiling and/or wall studs, to provide a rigid flush fit of the structural support ceiling fixture or alarm device box to the wall and/or ceiling stud.

SUMMARY OF THE INVENTION

In accordance with the foregoing objects, and others which may become apparent, the present invention includes a round truncated cylindrical structural support ceiling fixture electrical box housing, for mounting ceiling or wall electrical devices, such as ceiling lighting fixtures, wall sconces or alarm devices, wherein the housing box includes a recess therein for accommodating electrical wires within the recess.
The round, truncated cylindrical structural support box for ceiling fixtures, wall sconces or alarm devices, such as smoke, fire or carbon monoxide detection, contains a round cylindrical wall interrupted at a sector of arc of the cylinder with a flat portion. The round, truncated cylindrical structural support box has no external screw mounting bracket protrusions to interfere with the fitting of the structural support ceiling fixture box within pre-cut holes within a ceiling.
Typically, the structural support ceiling fixture electrical work box of the present invention includes fastener mounting bracket portions in the ceiling and/or wall stud bearing flat truncated portion. The box preferably contains one or more internal built-in angled fastener mounting bracket channel sheaths for accommodating fasteners, such as wood screws or nails, to wooden studs, or self tapping screws for metal studs. The angled mounting brackets extend at about 30 to 60 degrees, preferably about 45 degrees, so that the nails or screws can be easily mounted is that the need for external fastener mounting wings.
The structural support ceiling fixture electrical work box of the present invention is interchangeable, so that the structural support ceiling fixture electrical work box can be mounted on either the left or right side of the ceiling and/or wall stud. Therefore, the structural support ceiling fixture electrical work box can be reversed sideways in position.
The structural support ceiling fixture box includes one or more inwardly protruding channel wings with holes to accommodate fasteners for the electrical device, such as a ceiling lighting fixture or smoke/carbon monoxide alarm device. The open bottom of the box is flush with the building and/or ceiling wall, to allow the ceiling lighting fixture or alarm device to be firmly suspended therefrom.
The purpose of the cylindrical shape is to accommodate the wiring of the device in a ceiling hole. The truncated flat wall is molded integral with the ceiling box, so that the internal fastener mounting bracket within which the fastener, such as a nail or a screw, is inserted has a flat support surface.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention can best be understood in conjunction with the following drawings, in which:
FIG. 1 is a top perspective environmental view of the electrical box of the present invention, shown attached a ceiling wall stud;
FIG. 2 is an exploded front elevational view in cross section of the electrical box of FIG. 1, taken along directional view lines “2-2” of FIG. 1;
FIG. 3 is a top plan view of the structural support ceiling fixture box of the present invention as in FIGS. 1 and 2, taken along directional view arrow “3” of FIG. 2;
FIG. 4 is a front elevational view of the electrical box as in FIG. 3, taken along directional view arrow “4” of FIG. 3;
FIG. 5 is a bottom view of the box shown in FIGS. 1-4, taken along directional arrow “5” of FIG. 4;
FIG. 6 is a bottom view of an alternate embodiment for a truncated round electrical box having two pairs of opposite fixture mounting tabs.
FIG. 7 is a perspective view of an upwardly lit wall sconce lamp, mounted with the electrical box of the present invention;
FIG. 8 is a perspective view of a downwardly lit wall mounted lamp, attached to a stud by the electrical box of the present invention; and,
FIGS. 9-11 are diagrammatic front elevational views of the truncated round electrical box of the present invention, shown mounted respectively to the right of a building wall stud, above a connected brace between two adjacent wall studs, and to the left of a building wall stud.

DETAILED DESCRIPTION OF THE DRAWINGS

The structural support ceiling fixture electrical housing box 10 of the present invention includes a truncated cylindrical housing wall 11 extending continuous with a flat truncated sector wall 12. One or more interchangeable fastener mounting brackets 28, 30 are mounted within housing box 10 for accommodating holding fasteners 32, such as screws or nails, for mounting the ceiling fixture box 10, in particular, flush to, a building ceiling wall stud 36.
Work box 10 is interchangeable in that work box 10 can be used in old construction, which is retrofitted into an existing wall 36, wherein a generally round cut is made in the sheetrock ceiling and housing box 10 is attached to wall stud 36, within the cut, which cut is shaped to conform to the generally round shape of structural support ceiling fixture electrical housing box 10.
Because housing box 10 does not have any external protruding fastener mounting brackets, extending outside of the periphery of the outside cylindrical walls 11, work box 10 can be easily and snugly fit in place within the cut made within ceiling wall 36.
In the alternative, structural support ceiling fixture electrical housing box 10 may be used in new construction wherein housing box 10 is attached tightly to stud 36 of a ceiling.
In referring to FIGS. 1-5, work box 10 includes truncated flat mounting sector wall face 12 and round interrupted cylindrical wall 11. Flat mounting sector wall face 12 includes angled mounting brackets 28, 30 for holding screws within bores within extension sheath members 14 a and 16 a within brackets 28 and 30 respectively. Extension brackets 28, 30 extend from the interior side of truncated flat sector face 12 of the work box 10, within interior recess 10 a of housing box 10.
Mounting bracket module 28, and preferably a second fastener mounting bracket module 30, accommodate one or more mounting fasteners 32, such as screws or nails therein, wherein one fastener 32 is inserted within an extension sheath member 14 a and/or extension sheath member 16 a of respective internal screw mounting brackets 28 and/or 30 at an angle relative to the planar surface of truncated flat mounting sector wall 12, for screwing into a conventional ceiling stud 36.
A second fastener 32, such as a screw or nail, may be mounted within further internal screw mounting bracket 30 of housing box 10.
An advantageous feature of the truncated cylindrical structural support ceiling fixture housing box of the present invention is that the fastener mounting brackets 28, 30 are fully contained within the confines of the flat truncated cylindrical structural support ceiling fixture housing box 10, and the flat truncated wall 12 is flush with the stud 36 of the ceiling bearing wall, so that no protruding portion interferes with the positioning of round structural support ceiling fixture housing box 10 within the building wall.
As noted, fastener 32, such as screws or nails, may be mounted within a wood stud 36 and self-tapping screws (not shown) may be mounted within metal walls (not shown). Fasteners 32 must be mounted at an angle, generally about 45 degrees, although fasteners 32 may vary in range from 30 degrees to 60 degrees.
Because housing box 10 is recessed within the surface of the ceiling, generally sheetrock, it is difficult for physical access to insert a fastener, such as a hammer or a screwdriver, therefore the fastener must be inserted at a angle within interior recess 10 a of structural support ceiling fixture electrical work box 10.
Additionally, there is more structural stability of the mounting of work box 10 when fastener 32 is inserted at an angle within stud 34.
For ease of manufacturing, structural support ceiling fixture electrical work box 10 is made in a truncated cylindrical configuration, as shown in the drawing figures, wherein side wall 12 is generally flat.
Structural support ceiling fixture electrical housing box 10 also has conventional apertures with push-in clamping covers 80, 82, 84 and 86 forming apertures therein, to accommodate conventional incoming wires into and out of ceiling fixture housing box 10. These apertures receive electrical wires for attachment to the ceiling fixture or alarm device (not shown) attached to the housing box.
Therefore, the present invention is an improvement over the prior art because structural support ceiling fixture electrical work box 10 is interchangeable, whether it functions as an structural support ceiling fixture electrical work box for new work or old work. Conventional Madison-type clips may be used for securing the work box to the sheetrock. However because of the stability of the present configuration of structural support ceiling fixture electrical work box 10, auxiliary Madison clips may not be needed.
As shown in FIGS. 3 and 5, a pair of opposite fixture plate mounting brackets 60, 62 support a mounting plate of a lighting fixture or a smoke/fire/carbon monoxide alarm attached to electrical box 10.
However, as shown in FIG. 6, two pairs 60, 62 and 64, 68 of opposite fixture plate mounting brackets may be provided to mount lighting fixtures or alarms thereto.
Housing box 10 is a mirror image reversible, so that it may be mounted on either side of a ceiling stud.
Furthermore, various modifications may be made to the present invention, which will become apparent from the pending claims, without departing from the spirit and scope of the present invention, as is noted in appended claims.

Claims

1. A modular structural support electrical work box to support a light fixture or an alarm device in a ceiling or wall of a building, said structural support ceiling fixture electrical work box comprising:

a truncated cylindrical housing including a round wall truncated by a flat sector stud bearing side wall intersecting said truncated cylindrical wall;

said housing of said work box containing a recess therein for insertion of ceiling fixture or alarm electrical components, including wires therein;

said structural support ceiling fixture electrical housing box further having at least one internal angled fastener mounting bracket therein for inserting a mounting fastener within a ceiling wall stud to provide a rigid fit of said housing box to said wall stud;

said at least one fastener mounting bracket accommodating at least one mounting fastener therein; and,

said at least one fastener mounting bracket being located internally within said housing box, said housing box being attachable to said stud bearing ceiling wall, said at least one fastener mounting bracket including an angled sheath for said at least one mounting fastener for mounting said structural support ceiling fixture electrical housing box within a ceiling wall of the building.

2. The structural support ceiling fixture electrical work box as in claim 1 wherein said at least one fastener mounting bracket comprises a plurality of fastener mounting brackets.

3. The structural support ceiling fixture electrical work box as in claim 1 further comprising a recess for the placement of electrical wiring therein.

4. The structural support ceiling fixture electrical work box as in claim 1 wherein the bottom surface of said housing is substantially flush with the surface of said ceiling.

5. The structural support ceiling fixture electrical work box as in claim 1 wherein said at least one fastener mounting bracket extending at an angle between 30 and 60 degrees perpendicular to the plane of said ceiling.

6. The structural support ceiling fixture electrical work box as in claim 5, wherein said angle is about 45 degrees.