Electrical box mounting brace and bracket

Abstract

Disclosed are different configurations for a brace and mounting brackets for securing an electrical box in a support structure such as a wall or ceiling. The brace can include slidably brace members to provide an adjustable width. The mounting brackets can include different sets of connectors for mounting different sized electrical boxes.

Description

ELECTRICAL BOX MOUNTING BRACE AND BRACKETRELATED APPLICATION(S)[OOO1] This application is based on U.S. Provisional Application Serial No. 63 / 627456, filed January 31, 2024, the disclosure of which is incorporated herein by reference in its entirety and to which priority is claimed.FIELD

[0002] The present disclosure relates to a mounting brace assembly for an electrical box and a mounting bracket for use with the brace.BACKGROUND

[0003] Support braces for electrical boxes are typically installed between supports such as wall studs, trusses, and joists in the ceiling or other structures. Braces are also known for connecting to the bar supports used in suspended ceilings. Such braces can be awkward to install and may not provide the needed support for the intended device to be mounted to the electrical box.SUMMARY

[0004] Various configurations are directed to a brace and mounting brackets for securing an electrical box in a support structure such as a wall or ceiling. The brace caninclude slidably brace members to provide an adjustable width. The mounting brackets can include different sets of connectors for mounting different sized electrical boxes.

[0005] In certain configurations, a brace for an electrical box includes a first brace member and a second brace member. The first brace member includes a first central body and a first end bracket extending from the central body. The first central body has a first base, a first central ridge extending from the first base, a first arm extending from the first base, and a second arm extending from the first base. The second brace member includes a second central body and a second end bracket extending from the central body. The second central body has a second base, a second central ridge extending from the second base, a third arm extending from the second base, and a fourth arm extending from the second base. The first brace member is configured to slidably engage the second brace member.

[0006] In certain configurations, a mounting bracket for an electrical box includes a base having a plurality of openings configured to receive a fastener to connect an electrical box. A first set of connectors extend from the base. The first set of connectors have a first height. The first set of connectors are configured to releasably engage a mounting brace. A second set of connectors extend from the base. The second set of connectors have a second height different than the first height. The second set of connectors are configured to releasably engage the mounting brace.

[0007] In certain configurations, an electrical box mounting assembly includes a first brace member and a second brace member. The first brace member has a first centralbody and a first end bracket extending from the central body. The first central body has a first base, a first central ridge extending from the first base, a first arm extending from the first base, and a second arm extending from the first base. The second brace member has a second central body and a second end bracket extending from the central body. The second central body having a second base, a second central ridge extending from the second base, a third arm extending from the second base, and a fourth arm extending from the second base. The first brace member is configured to slidably engage the second brace member. A mounting bracket has a base, a first set of connectors extending from the base, and a second set of connectors extending from the base. The first set of connectors and the second set of connectors are configured to releasably secure the mounting bracket to the first brace member and the second brace member.

[0008] In certain implementations, A method of installing an electrical box includes connecting an electrical box to a mounting bracket. The mounting bracket has a base, a first set of connectors extending from the base, and a second set of connectors extending from the base. The mounting bracket is positioned in an orientation dependent on the depth of the box to secure either the first set of connectors or the second set of connectors. The first set of connectors are used for a box having a first depth and the second set of connectors are used for a box having a second depth less than the first depth. Either the first set of connectors or the second set of connectors are releasably secured to a mounting brace.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The aspects and features of various exemplary embodiments will be more apparent from the description of those exemplary embodiments taken with reference to the accompanying drawings.

[0010] FIG. 1 is a perspective view of a mounting brace.

[0011] FIG. 2 is an exploded view of the mounting brace.

[0012] FIG. 3 is a front view of a brace member of the mounting brace.

[0013] FIG. 4 is a perspective view of a mounting bracket.

[0014] FIG. 5 is a front view of the mounting bracket of FIG. 4.

[0015] FIG. 6 is a perspective view of the mounting bracket of FIG. 4 connected to an electrical box and connected to the mounting brace.

[0016] FIG. 7 is a perspective view of a mounting bracket.

[0017] FIG. 8 is a side view of the mounting bracket of FIG. 7.

[0018] FIG. 9 is a front view of the mounting bracket of FIG. 7.

[0019] FIG. 10 is a perspective view of the mounting bracket of FIG. 7 connected to an electrical box and connected to the mounting braceDETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0020] Braces are used to install electrical boxes between supports in various residential and commercial applications. The electrical boxes can be used to connect outlets, switches, sensors, lighting fixtures, and other electrical devices. In certainconfigurations, a brace assembly includes a mounting and support structure for connecting to supports. The brace assembly is configured for supporting electrical devices while electrical connections can be made in the electrical box.

[0021] FIGS. 1-3 show an exemplary configuration of a mounting brace 100 having a first brace member 102 and a second brace member 104. The first brace member 102 is configured to slidably receive the second brace member 104. The width of the brace 100 can be adjusted by sliding the brace members 102, 104 relative to one another in a given support area.

[0022] In certain configurations, each brace member 102, 104 can include a central body 106 and an end bracket 108 extending from the central body 106. Each central body 106 can include a base 110, a central ridge 112 extending from the base 110, a first arm 114 extending on a first side of the base no and a second arm 116 extending on a second side of the base no.

[0023] As best shown in FIG. 1, the second brace member 104 can be configured to be positioned inside and at least partially on top of the first brace member 102. As best shown in FIG. 2, the first brace member 102 can include a slot 118 and the second brace member 104 can include downwardly extending clip 120. When adjusting the width of the brace members 102, 104, the clip 120 can engage the slot 118 to prevent disengagement of the first and second brace members 102, 104. This can help during installation to prevent the parts from falling apart when being positioned by a user.

[0024] As best shown in FIGS. 2 and 3, the central ridge 112 extends above the base 110 of each brace member 102, 104. The central ridge extends 112 to an interior end of the brace member 102, 104 and is spaced from the exterior end of the brace member 102, 104. The central ridge 112 has a rounded exterior edge. A plurality of openings 122 are provided in the central ridge 112. The openings 122 can receive fasteners to secure an electrical box directly to the brace 100.

[0025] As best shown in FIG. 3, the first arm 114 and the second arm 116 extend from an outer edge of the base 110 and above the central ridge 112. In certain configurations, each arm 114, 116 includes a first portion 124 extending from the base 110 and a second portion 126 extending from the first portion 124. The first portion 124 can extend away from the base 110 at an oblique angle and the second portion 126 can extend from the first portion 124 toward the base 110. The first and second portions 124, 126 can at least partially define a channel extending along the length of the brace members 102, 104.

[0026] The end bracket 108 can be integrally formed with the central body 106 or can be separate and connected with mechanical fasteners or through welding. At least a portion of the end bracket 108 can extend substantially perpendicular to the central body 106. The end brackets 108 include a central section 128, a first outer portion 130, a second outer portion 132, and a bottom flange 134.

[0027] The central section 128 can be bent inwardly relative to the outer portions 130, 132 and can act as a reinforcement rib to provide greater support to the brace 100. The end flange 134 can extend substantially perpendicular to the first and second outerportions 130, 132. Openings 136 can be provided in the outer portions 130, 132 and the end flange 134. The openings 136 are configured to receive fasteners to connect the end bracket 108 to a support structure, such as a stud, joist, I-beam, or drop ceiling support bar.

[0028] In certain implementations an adhesive member 138 can be applied to the central section 128. The adhesive member 138 can include a double-sided adhesive tape with a cover positioned on the outer portion. During installation, a user can remove the outer cover and engage the adhesive members 138 on each brace member 102, 104 with a respective surface of a connecting support. The adhesive members 138 can hold the brace members 1024, 104 in place while fasteners are inserted through the openings 136 to secure the mounting brace 100 to the supports. This can provide a hands-free installation in that the brace 100 does not need to be supported by the user when fastening to a support structure.

[0029] In certain implementations, the structure of the mounting brace can provide greater support than other braces. The structure can also permit manufacture in different lengths as needed and via a progress die molding and stamping procedure.

[0030] Various installations can utilize mounting brackets to connect an electrical box to the mounting brace 100. The mounting brackets can include different features that allow different sizes of electrical boxes to be connected. For example, the mounting bracket can be connected to the mounting brace in a first orientation to connect a first size electrical box or connected to the mounting brace in a second orientation to connecta second size electrical box. The different size electrical boxes can be, for example, 2.125 inch deep or 1.5 inch deep electrical box. The different orientations allow for different electrical boxes to be mounted at a consistent position without structural modifications by a user in the field.

[0031] In certain implementations, the mounting brackets are configured to be releasably clipped to the mounting brace. For example, the mounting bracket can include a plurality of clips that are configured to engage the first and second arms of the mounting brace. Different clips can be used depending on the electrical box to be mounted.

[0032] FIGS. 4 and 5 show an exemplary configuration of a mounting bracket 200. The mounting bracket 200 includes a base 202. A plurality of openings 204 are formed in the base 202 which can receive fasteners to secure the mounting bracket 200 to an electrical box. Different openings 204 can be used with different boxes.

[0033] A plurality of connectors extend from the base 202. The connectors are configured to releasably engage the mounting brace 100. In the configurations shown in FIGS. 4 and 5, the connectors extend along an axis with a first set of connectors 206 positioned on the exterior of the bracket and a second set of connectors 208 positioned on the interior of the bracket. Each outer and inner connector 206, 208 extends from one side of the base 202 with an opposing connector 206, 208 on the opposite side. The inner connectors 208 extend above the outer connectors 206. The outer connectors 206 can be used to mount a first electrical box having a first depth and the inner connectors208 can be used to mount a second electrical box having a second depth less than the first depth.

[0034] In certain configurations, the outer connectors 206 include an outer clip support 210, an outer clip neck 212, and an outer clip head 214. The clip support 210 extends outwardly and up from the base 202 at an oblique angle. The clip neck 212 extends up from the support 210 and toward the center of the base 202. The clip head 214 extends upwardly from the neck. The clip head 214 includes a first prong and a second prong. The first and second prong each extend down toward the base 202 and include an angled tip.

[0035] In certain configurations, the inner connectors 208 include an inner clip support 216, an inner clip neck 218, and an inner clip head 220. The clip support 216 extends up from the base 202. The clip neck 218 extends up from the support 216 and toward the center of the base 202. The clip head 220 extends up from the neck 218. The clip head 220 includes a first prong and a second prong. The first and second prong each extend down toward the base and include an angled tip.

[0036] In certain configurations, one or more ledges can be formed adjacent the inner connectors 208. In the illustrated embodiment a first set of outer ledges 222, a second set of outer ledges 224, and a set of inner ledges 226 can be used. The ledges 222, 224, 226 extend from the inner clip supports 216 and out toward the center of the base 202. The ledges 222, 224, 226 extend above the outer connectors 206. When connected to a mounting brace 100, the ledges 222, 224, 226 can engage or bepositioned near the bottom of the brace 100 to help limit the movement of the bracket 200 during installation.

[0037] FIG. 6 shows an example of an electrical box 230 connected to the mounting brace 100 via the mounting bracket 200. During installation, a user can connect the mounting bracket 200 to an electrical box 230. Fasteners can be inserted through the electrical box 230 and into the base 202 of the mounting bracket 200. The electrical box 230 and mounting bracket 200 can then be clipped to the mounting brace 100 by engaging the appropriate clips 206, 208 with the arms 114, 116 of the mounting brace 100. The angled tips on the prongs of the clip heads 220 can extend around an outer edge of the arms 114, 116 to secure the mounting bracket 200 to the brace 100. To connect a deeper electrical box, the outer clips 206 can be used and clipped to the arms 114, 116.

[0038] Accordingly, different orientations of the mounting bracket 200 can be used to install electrical boxes having different depths. The orientation of the mounting bracket 200 can select the appropriate height of the clips 206, 208 to match the depth of the electrical box so that the position of an outer edge of the electrical box is substantially consistent relative to the brace 100. This can place the electrical box at the appropriate position relative to the ceiling, wall, or other finished structure.

[0039] Use of the mounting bracket 200 can also eliminate the need for a user in the field to bend or alter the brace member too to adjust the position of different sizedelectrical boxes. Eliminating the need to make the brace 100 adjustable in the field can allow for easier manufacture and a stronger brace 100.

[0040] FIGS. 7-9 show an exemplary configuration of a mounting bracket 300. The mounting bracket 300 includes a base 302. A plurality of openings 304 are formed in the base 302 which can receive fasteners to secure the mounting bracket 300 to an electrical box. Different openings 304 can be used with different boxes.

[0041] A plurality of connectors extend from the base 302. The connectors are configured to releasably engage the mounting brace 100. In the configurations shown in FIGS. 7-9, the connectors extend along a first axis and a second axis with a first set of connectors 306 positioned along a first axis of the bracket 300 and a second set of connectors 308 positioned along a second axis of the bracket. Each first and second connector 306, 308 extends from one side of the base 302 with an opposing connector 306, 308 on the opposite side. The first and second connectors 306, 308 are oriented substantially perpendicular to one another, with the body 302 having a cross shape. The second connectors 308 extend above the first connectors 306. The first connectors 306 can be used to mount a first electrical box having a first depth and the second connectors 308 can be used to mount a second electrical box having a second depth less than the first depth.

[0042] In certain configurations, the first connectors 306 include a first clip support 310, a first clip neck 312, and a first clip head 314. The clip support 310 extends outwardly and up from the base 302 at an oblique angle. The clip neck 312 extends upfrom the support 310 and toward the center of the base 302. The clip head 314 extends upwardly from the neck 312. The clip head 314 includes a first prong and a second prong. The first and second prong each extend down toward the base 302. In certain configurations, all of the prongs can include an angled tip or only some of the prongs can include an angled tip. For example, as best shown in FIG. 8, the angled tips can be included on one side of the first connectors 306 only.

[0043] In certain configurations, the second connectors 308 include a second clip support 316, a second clip neck 318, and a second clip head 320. The clip support 316 extends up from the base 302. The clip neck 318 extends up from the support 316 and toward the center of the base 302. The clip head 320 extends up from the neck 318. The clip head 320 includes a first prong and a second prong. The first and second prong each extend down toward the base. In certain configurations, all of the prongs can include an angled tip or only some of the prongs can include an angled tip. For example, as best shown in FIG. 9, the angled tips can be included on one side of the second connectors 308 only.

[0044] In certain configurations, the second clip supports 316 can include a ledge 322. The ledges 322 extend substantially parallel to the base 302. The ledges 322 extend above the first connectors 306. When connected to a mounting brace 100, the ledges 322 can engage or be positioned near the bottom of the brace 100 to help limit the movement of the bracket 300 during installation.

[0045] FIG. 10, shows an example of an electrical box 330 connected to the mounting brace 100 via the mounting bracket 300. During installation, a user can connect the mounting bracket 300 to an electrical box 330. Fasteners can be inserted through the electrical box 330 and into the base 302 of the mounting bracket 300. The electrical box 330 and mounting bracket 300 can then be clipped to the mounting brace 100 by engaging the appropriate clips 306, 308 with the arms 114, 116 of the mounting brace 100. The angled tips on the prongs of the clip heads 320 can extend around an outer edge of the arms 114, 116 to secure the mounting bracket 300 to the brace 100. To connect a deeper electrical box, the mounting bracket can be turned 90 degrees so that the first connectors 306 are used instead of the second connectors 308.

[0046] Accordingly, different orientations of the mounting bracket 300 can be used to install electrical boxes having different depths. The orientation of the mounting bracket 300 can select the appropriate height of the clips 306, 308 to match the depth of the electrical box so that the position of an outer edge of the electrical box is substantially consistent relative to the brace 100. This can place the electrical box at the appropriate position relative to the ceiling, wall, or other finished structure.

[0047] Use of the mounting bracket 200 can also eliminate the need for a user in the field to bend or alter the brace member 100 to adjust the position of different sized electrical boxes. Eliminating the need to make the brace 100 adjustable in the field can allow for easier manufacture and a stronger brace 100.

[0048] Other configurations of mounting brackets can be used than what is shown in the illustrated examples. Changings in the configuration of the clips, the orientation of the clips, and the size and spacing of the brackets can be adjusted as needed to accommodate different electrical boxes and different mounting implementations.

[0049] The foregoing detailed description of the certain exemplary configurations and implementations has been provided for the purpose of explaining the general principles and practical application, thereby enabling others skilled in the art to understand the disclosure for various embodiments and with various modifications as are suited to the particular use contemplated. This description is not necessarily intended to be exhaustive or to limit the disclosure to the exemplary embodiments disclosed. Any of the embodiments and / or elements disclosed herein may be combined with one another to form various additional embodiments not specifically disclosed. Accordingly, additional embodiments are possible and are intended to be encompassed within this specification and the scope of the appended claims. The specification describes specific examples to accomplish a more general goal that may be accomplished in another way.

[0050] As used in this application, the terms “front,” “rear,” “upper,” “lower,” “upwardly,” “downwardly,” and other orientational descriptors are intended to facilitate the description of the exemplary embodiments of the present disclosure, and are not intended to limit the structure of the exemplary embodiments of the present disclosure to any particular position or orientation. Terms of degree, such as “substantially” or“approximately” are understood by those of ordinary skill to refer to reasonable ranges outside of the given value, for example, general tolerances associated with manufacturing, assembly, and use of the described embodiments. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.

Claims

What is Claimed:

1. A brace for an electrical box comprising: a first brace member having a first central body and a first end bracket extending from the central body, the first central body having a first base, a first central ridge extending from the first base, a first arm extending from the first base, and a second arm extending from the first base; and a second brace member having a second central body and a second end bracket extending from the central body, the second central body having a second base, a second central ridge extending from the second base, a third arm extending from the second base, and a fourth arm extending from the second base, wherein the first brace member is configured to slidably engage the second brace member.

2. The brace of claim 1, wherein the first central ridge extends from a first end of the base and is spaced from a second end of the base.

3. The brace of claim 1, wherein the first central ridge includes a plurality of fastener openings.

4. The brace of claim 1, wherein the first arm includes a first portion extending at an angle away from the base and a second portion extending at angle from the first portion toward the base.

5. The brace of claim 1, wherein the end bracket includes a central section, a first outer portion, a second outer portion, and a bottom flange.

6. The brace of claim 5, wherein the central section is recessed from the first outer portion and the second outer portion.

7. A mounting bracket for an electrical box comprising: a base having a plurality of openings configured to receive a fastener to connect an electrical box; a first set of connectors extending from the base, the first set of connectors having a first height, the first set of connectors configured to releasably engage a mounting brace; and a second set of connectors extending from the base, the second set of connectors having a second height different than the first height, the second set of connectors configured to releasably engage the mounting brace.

8. The mounting bracket of claim 7, wherein the first set of connectors include a clip head configured to releasably engage the mounting brace.

9. The mounting bracket of claim 8, wherein the clip head includes a first prong and a second prong.

10. The mounting bracket of claim 7, wherein the first set of connectors are positioned on the exterior of the base and the second set of connectors are positioned on the interior of the base.

11. The mounting bracket of claim 7, wherein a ledge extends from the second connectors.

12. The mounting bracket of claim n, wherein the ledge is positioned at a height above an upper edge of the first connectors and below an upper edge of the second connectors.

13. The mounting bracket of claim 7, wherein the first connectors are oriented substantially perpendicular to the second connectors.

14. The mounting bracket of claim 7, wherein the first connectors include a clip support and a clip head extending from the clip support.

15. A electrical box mounting assembly comprising: a first brace member having a first central body and a first end bracket extending from the central body, the first central body having a first base, a first central ridge extending from the first base, a first arm extending from the first base, and a second arm extending from the first base; a second brace member having a second central body and a second end bracket extending from the central body, the second central body having a second base, a second central ridge extending from the second base, a third arm extending from the second base, and a fourth arm extending from the second base, wherein the first brace member is configured to slidably engage the second brace member; and a mounting bracket having a base, a first set of connectors extending from the base, and a second set of connectors extending from the base, wherein the first set of connectors and the second set of connectors are configured to releasably secure the mounting bracket to the first brace member and the second brace member.

16. The electrical box mounting assembly of claim 15, wherein the first set of connectors are configured to position a first electrical box having a first depthrelative to the brace and the second set of connectors are configured to position a second electrical box having a second depth less than the first depth relative to the brace.

17. The electrical box mounting assembly of claim 15, wherein the first connectors are oriented perpendicular to the second connectors.

18. A method of installing an electrical box comprising: connecting an electrical box to a mounting bracket, the mounting bracket having a base, a first set of connectors extending from the base, and a second set of connectors extending from the base; positioning the mounting bracket in an orientation dependent on the depth of the box to secure either the first set of connectors or the second set of connectors, wherein the first set of connectors are used for a box having a first depth and the second set of connectors are used for a box having a second depth less than the first depth; releasably securing either the first set of connectors or the second set of connectors to a mounting brace.

19. The method of claim 18, wherein releasably securing either the first set of connectors or the second set of connectors to a mounting brace includes clipping the relative connectors to arms of the mounting brace.

20. The method of claim 18, wherein positioning the mounting bracket includes placing the mounting bracket in a first orientation or in a second orientation perpendicular to the first orientation.