Surface-mounted electrical device support assembly

Abstract

An electrical device support assembly for securing to a surface is provided. The assembly includes a support bracket having an outer rim, a main region, an inner region, and one or more first apertures configured to secure the support bracket to a pair of structural supports. The outer rim surrounds the main region. The main region surrounds the inner region. The interior region includes one or more second apertures configured for mechanically connecting the electrical device to the support bracket.

Description

Technical Field

[0001] The present disclosure relates to supports for electrical devices. More particularly, the present disclosure relates to surface mounted electrical device support assemblies. Background Art

[0002] Electrical junction boxes are commonly installed in walls and ceilings. Electrical conductors may be passed from a service panel through a wall and / or ceiling to terminate in a junction box. Electrical devices (such as, but not limited to, outlets, lights, fans, etc.) may be operably connected to the electrical conductors in the junction box in a known manner.

[0003] When installed in a ceiling, the junction box may be subject to varying degrees of forces exerted by the electrical devices.

[0004] Some ceiling junction boxes are configured to support electrical devices, such as, but not limited to, recessed or semi-recessed light fixtures, which typically only apply vertical and / or static loads to the junction box, i.e., only light forces are applied to the junction box. These junction boxes are typically only attached to one ceiling joist. For ease of discussion, this type of junction box is referred to herein as "lightweight."

[0005] Other ceiling junction boxes are configured to support electrical devices that impose heavy vertical loads and / or dynamic forces such as rotational forces on the junction box. For example, these junction boxes may be operably connected to electrical devices such as, but not limited to, ceiling fans, combination fan / lighting equipment, high-weight ceiling lights, and other high-load-imposing equipment. These junction boxes are typically secured to two adjacent ceiling joists. For ease of discussion, this type of junction box is referred to herein as "heavy duty."

[0006] Lightweight ceiling junction boxes are typically more expensive to purchase and install than heavy-duty ceiling junction boxes. Therefore, builders often minimize construction costs by installing only the less expensive lightweight ceiling junction boxes—in conjunction with electrical devices that apply light forces.

[0007] Once installed, and covered by drywall, it can be difficult to determine whether a junction box is lightweight or heavy duty.

[0008] Homeowners who wish to upgrade from lightweight builder-installed electrical fixtures to heavier electrical fixtures such as chandeliers and / or ceiling fans face the challenge of either mounting the heavy equipment to a lightweight junction box or removing drywall to replace / inspect the junction box to determine its rating.

[0009] More recently, mounts have been proposed for mounting supports for such heavy electrical equipment to the surface of a ceiling, such as disclosed in Applicant's own US Pat. No. 7,271,350.

[0010] However, the present disclosure has determined that there is a need for an improved surface mounted electrical device support that overcomes and / or mitigates one or more deficiencies and deleterious effects of prior art junction boxes and / or supports. Summary of the invention

[0011] An electrical device support assembly for attachment to a surface is provided. The assembly includes a support bracket having an outer edge, a main region, an inner region, and one or more first openings configured as a pair of structural supports for attaching the support bracket to the surface. The outer edge surrounds the main region, and the main region surrounds the inner region. The inner region includes one or more second openings configured for mechanically attaching the electrical device to the support bracket.

[0012] In some embodiments, alone or in combination with any one or more of the preceding and / or following embodiments, one or more first openings are in an outer edge or main region.

[0013] In some embodiments, alone or in combination with any one or more of the foregoing and / or following embodiments, the interior region has a first window through which electrical leads of the electrical device can pass.

[0014] In some embodiments, alone or in combination with any one or more of the foregoing and / or following embodiments, the main area includes a plurality of first windows through which electrical leads of the electrical device can pass.

[0015] In some embodiments, alone or with any one or more of the preceding and / or following embodiments, the plurality of first windows is a plurality of knockout holes.

[0016] In some embodiments, alone or in combination with any one or more of the foregoing and / or following embodiments, the outer edge is offset from the main region by a first distance along the axis, and the main region is offset from the inner region by a second distance along the axis.

[0017] In some embodiments, alone or in combination with any one or more of the foregoing and / or following embodiments, the first distance provides a space through which an electrical lead can pass.

[0018] In some embodiments, alone or in combination with any one or more of the foregoing and / or following embodiments, the assembly further includes a cover plate positioned on the outer edge to define an enclosed space in the support bracket.

[0019] In some embodiments, alone or in combination with any one or more of the preceding and / or following embodiments, the cover is between the surface and the supporting bracket, or the bracket is between the surface and the cover.

[0020] In some embodiments, alone or in combination with any one or more of the foregoing and / or following embodiments, a center-to-center distance of the first openings is equal to a center-to-center distance (D) of a pair of structural supports.

[0021] In some embodiments, alone or in combination with any one or more of the foregoing and / or following embodiments, the support bracket is configured such that the outer edge extends into the main block to define ears on opposite sides of the portion of the outer edge having at least one first opening.

[0022] In some embodiments, alone or in combination with any one or more of the preceding and / or following embodiments, the support bracket is formed as a single piece of galvanized steel.

[0023] In some embodiments, alone or in combination with any one or more of the foregoing and / or following embodiments, the assembly further comprises a decorative cover sized to conceal the support bracket and having a second window sized and positioned to align with an interior area of ​​the support bracket when the cover is removably connected to the support bracket.

[0024] In some embodiments, alone or in combination with any one or more of the foregoing and / or following embodiments, the decorative cover has an integrally formed connector that is removably connectable to the support bracket.

[0025] An electrical device support assembly for being fixed to a surface is provided. The assembly includes a support bracket having an outer edge, a main area, and an inner area, the outer edge surrounding the main area, and the main area surrounding the inner area. A first opening is in the main area and is configured to be a pair of structural supports that fix the support bracket to the surface. The center-to-center distance of the first opening is equal to the center-to-center distance (D) of the pair of structural supports. The first distance causes the outer edge to deviate from the main area in a first direction. Two second openings in the main area are configured to mechanically connect the electrical device to the support bracket. The grounding terminal in the main area is configured for the grounding connection of the electrical device. The cover plate on the outer edge defines an enclosed space in the support bracket. The enclosed space is defined by the first distance and is located between the main area of ​​the bracket against the surface and the cover. A plurality of knockout holes are located in the main area, and electrical leads of the electrical device can pass through the knockout holes.

[0026] In some embodiments, alone or in combination with any one or more of the foregoing and / or following embodiments, the support bracket comprises a second distance that offsets the inner region in the first direction from the main region.

[0027] In some embodiments, alone or in combination with any one or more of the preceding and / or following embodiments, the support bracket is formed as a single piece of galvanized steel.

[0028] In some embodiments, alone or in combination with any one or more of the foregoing and / or following embodiments, the primary region is an x-shaped structure having ground terminals and at least two second openings on alternating legs of the x-shaped structure.

[0029] In some embodiments, alone or in combination with any one or more of the foregoing and / or following embodiments, the assembly further comprises a decorative cover sized to conceal the support bracket and having a second window sized and positioned to align with an interior area of ​​the support bracket when the cover is removably connected to the support bracket.

[0030] In some embodiments, alone or in combination with any one or more of the foregoing and / or following embodiments, the trim cover has an integrally formed lip that is removably connected to an outer edge of the support bracket.

[0031] Those skilled in the art will appreciate and understand the foregoing and other features and advantages of the present disclosure from the following detailed description, drawings and appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 is an exploded view of an exemplary embodiment of a surface mount support assembly according to the present disclosure in a first use position;

[0033] Figure 2 yes Figure 1 a bottom perspective view of an exemplary embodiment of a support bracket of an assembly;

[0034] Figure 3 yes Figure 2 A top perspective view of a support bracket;

[0035] Figure 4 It is along Figure 3 The line 4-4 in Figure 2 A cross-sectional view of a support bracket;

[0036] Figure 5 It is along Figure 3 The line 5-5 in Figure 2 A cross-sectional view of a support bracket;

[0037] Figure 6 Related to the fan mounting cover Figure 2 A bottom perspective view of a support bracket;

[0038] Figure 7 It is in the second use position Figure 1 A partial exploded view of the components;

[0039] Figure 8 yes Figure 1a bottom perspective view of an exemplary embodiment of a decorative cover of an assembly;

[0040] Fig. 9 yes Figure 8 An enlarged view of an exemplary embodiment of a connector for a decorative cover;

[0041] Fig.10 is an exploded view of an alternative exemplary embodiment of a surface mount support assembly according to the present disclosure;

[0042] Fig.11 yes Fig.10 A partial exploded view of the components;

[0043] Fig.12 Related to the fan mounting cover Fig.10 A bottom perspective view of a support bracket;

[0044] Fig.13 yes Fig.12 A side view of a support bracket;

[0045] Fig.14 yes Fig.12 A top perspective view of a support bracket;

[0046] Fig.15 yes Fig.10 a bottom perspective view of an exemplary embodiment of a decorative cover of an assembly;

[0047] Fig.16 It is used in Fig.10 A bottom perspective view of another exemplary embodiment of a support bracket in an assembly of;

[0048] Fig.17 is an exploded view of another exemplary embodiment of a surface mount support assembly according to the present disclosure;

[0049] Fig.18 yes Fig.17 A bottom perspective view of a support bracket;

[0050] Fig.19 yes Fig.17 A top perspective view of a support bracket;

[0051] Fig. 20 yes Fig.17 A partial exploded view of the components;

[0052] Fig.21 yes Fig.17 a bottom perspective view of an exemplary embodiment of a trim cover of an assembly; and

[0053] Fig. 22 yes Fig.21 A sectional view of the edge area of ​​the decorative cover. DETAILED DESCRIPTION

[0054] With reference to the accompanying drawings, in particular Figure 1 , an exemplary embodiment of a surface mount support assembly according to the present disclosure is shown and generally indicated by the reference numeral 10 .

[0055] The assembly 10 includes a support bracket 12 and, in some embodiments, one or more fasteners 14, a decorative cover 16, and / or one or more ground terminals 18. The assembly 10 is configured such that the support bracket 12 can be mounted to two structural supports 20 via the fasteners 14, against a surface 22, thereby allowing connection between an electrical device 24 and a junction box 26.

[0056] Advantageously, the assembly 10 can be used to install heavy duty electrical devices 24 without removing or replacing lightweight boxes 26 and without damaging the surface 22. Rather, the assembly 10 provides a mechanical connection of the heavy duty required electrical device 24 to the support 20 to enable the electrical device to be electrically connected to the lightweight rated junction box 26.

[0057] In the illustrated embodiment, support 20 is a ceiling joist, surface 22 is ceiling drywall, electrical device 24 is a fan, and junction box 26 is a light-grade box. Of course, the present disclosure contemplates that assembly 10 can be used with other supports 20, surfaces 22, electrical devices 24, and junction boxes 26.

[0058] Also refer to Figure 2-Figure 6 The support bracket 12 is described in detail. The bracket 12 has an outer edge 30, a main region 32 and an inner region 34.

[0059] Outer rim 30 surrounds main region 32 and is offset from main region a first distance 36 along axis A. Main region 32 surrounds inner region 34 and is offset from inner rim a second distance 38 along axis A. Inner region 34 includes a first window 40 through which electrical leads 42 of electrical device 24 can pass.

[0060] The outer edge 30 includes an end 44 having a first aperture 46 configured to receive a fastener 14 to secure the bracket 12 to the support 20. In the illustrated embodiment, each end 44 includes two first apertures 46 such that the bracket 12 is secured to the support 20 by four fasteners 14. Of course, the present disclosure contemplates that the assembly 10 has any desired number of fasteners 14 and first apertures 46.

[0061] The supports 20 are typically mounted at a predetermined center-to-center distance (D) from each other. Common center-to-center distances (D) include 12 inches, 16 inches, 24 inches, etc. Thus, the assembly 10 can have any length that satisfies the center-to-center distance (D) of each support 20 to which the assembly is mounted. In short, the first opening 46 preferably has a center-to-center distance (D) selected from the group consisting of 12 inches, 16 inches, 24 inches, and other desired sizes.

[0062] In some embodiments, Figure 5 As shown, the bracket 12 can be configured so that the outer edge 30 extends into the main block 32 to define ears 50 on opposite sides of the portion of the outer edge having the first opening 46. The ears 50 provide two wall segments 52 in the outer edge 30 outside the opening 46. Without wishing to be bound by any particular theory, the wall segments 52 are believed to provide increased bending resistance to the outer edge 30 in the range of the first opening 46.

[0063] In some embodiments, the bracket 12 may include one or more ground terminals 18 for grounding the bracket 12, the electrical device 24, and the electrical leads 42 in a known manner. In the illustrated embodiment, the terminals 18 are shown as an example on the inner region 34. Of course, the present disclosure contemplates that the terminals 18 are formed on any portion of the bracket 12.

[0064] The interior region 34 further includes a second opening 56 configured for connection to the electrical device 24. Figure 6 , shows an exemplary connection between a portion of an electrical device 24 in the form of a fan support ball 24-1 having leads 42 and the assembly 10. The fan support ball end 24-1 is typically supported in a receiver 24-2, as is known from the applicant's own U.S. Patent No. 9,371,962. Figure 6 As shown, the receiver 24 - 2 may be secured to the support bracket 12 at the second opening 56 of the interior region 34 using one or more second fasteners 58 .

[0065] In some embodiments, Figure 4 As shown, the bracket 12 can be configured so that the portion of the interior region 34 having the second opening 56 is supported on each side by at least two wall segments 62 from the outer edge 30. Without being limited to any particular theory, the wall segments 62 are believed to provide increased bending resistance to the interior region 34 in the area of ​​the second opening 56.

[0066] In some embodiments, the bracket 12 is preferably formed as a single piece - but it is contemplated that the bracket is formed from multiple sections. The bracket 12 can be made of any material having sufficient strength for the desired heavy-duty application. For example, the bracket 12 can be formed from metal and / or polymers. The bracket 12 can be formed by molding, stamping, casting, drawing, and other known processes. In a specific example, the bracket 12 is formed from a single piece of galvanized steel that is stamped, drawn, or molded.

[0067] In such Figure 1 In some examples shown, the terminal box 26 is positioned between the supports 20 such that the surface 22 has an opening 22-1 that is concentric with the first window 40 of the support bracket 12 along the axis A. The concentric alignment of the opening 22-1 and the first window 40 allows electrical connection from the device 24 to the terminal box 26 in a normal or ordinary manner.

[0068] However, the present disclosure contemplates that the assembly 10 may be equally used in other installations, such as Figure 7 Here, the surface 22 has an opening 22-2 offset along the axis A relative to the window 40 of the support bracket 12. Figure 4 and Figure 5 As described, the bracket 12 includes a first distance 36 between the outer edge 30 and the main area 32 - and a second distance 38 between the main area and the inner area 34. Thus, in this manner, the bracket 12 provides a space between the main area 32 and the surface 22 through which the electrical leads 42 of the electrical device 24 (once extended through the window 40) can pass within the bracket to the opening 22-2, and thereby to the junction box 26.

[0069] In some embodiments, the assembly 10 may include a cover plate 28 that can be positioned between the surface 22 and the bracket 12. When the cover plate 28 is present, the cover plate covers the surface 22 so that the electrical leads 42 pass between the bracket 12 and the panel without contacting the surface, such as Figure 6 Cover plate 28 may include one or more knockout holes (not shown) to allow a user to select the location of opening 28-1 that aligns with opening 22-1. Cover plate 28 may be secured to surface 22 in any desired manner.

[0070] Thus, the assembly 10 is configured to pass the electrical leads 42 from the device 24 through the window 40 and through the opening 22-1 (when the opening is aligned with the window), or through the opening 22-2, and then between the main area 32 and the surface 22 to the opening 22-2 (when the opening is not aligned with the window). From either opening 22-1, 22-2, the electrical leads 42 can be electrically connected to the line and load conductors in the junction box 26. In short, the assembly 10 is configured to allow electrical connection between the device 24 and the junction box 26, while providing a mechanical connection to the support 20.

[0071] In some embodiments, the assembly 10 may further include a decorative cover 16 that conceals or otherwise provides a decorative appearance to the assembly. Figure 1 , Figure 8 and Fig. 9 A cover 16 is depicted. The cover 16 may be in the form of a decorative medallion as is known in the art.

[0072] The cover 16 is removably connectable to the support bracket 12 and is sized and configured to conceal the support bracket 12 when connected except for a portion that is connectable to and shielded by the electrical device 24 .

[0073] The cover 16 has an outer periphery 64 , an interior cavity 66 , a second window 68 , and one or more connectors 70 .

[0074] The perimeter 64 is larger than the outer dimensions of the stent 12. The cavity 66 has a sufficient volume to receive the stent 12 therein.

[0075] The second window 68 is sized so that when the cover 16 is removably connected to the bracket 12, the interior region 34 of the bracket extends into the cover at the second window - and in some embodiments beyond the outer surface of the cover.

[0076] The connector 70 can be removably connected to a corresponding connector 72 defined on the bracket 12. In the illustrated embodiment, the connector 70 is shown as a push pin and the connector 72 is shown as a third opening. Of course, the present disclosure contemplates that the cover 16 is removably connected to the bracket 12 in any desired manner.

[0077] When installed, the cover 16 can conceal the bracket 12 so that the bottom edge 74 of the cover is in contact with the surface 22. In some embodiments, the connectors 70, 72 can provide a biasing force to keep the edge 74 in contact with the surface.

[0078] For example, the cover 16 can be formed of metal and / or polymer. The cover 16 can be formed by molding, stamping, casting, drawing and other known processes. In a specific example, the cover 16 is formed of a single piece of molded insulating material, such as but not limited to plastic, polyurethane and other materials.

[0079] Reference now Figure 10-15 , an alternative exemplary embodiment of a surface mount support assembly according to the present disclosure is shown and generally indicated by the reference numeral 110 .

[0080] The assembly 110 includes a support bracket 112 and, in some embodiments, one or more fasteners 114, a decorative cover 116, and / or one or more ground terminals 18. The assembly 110 is configured such that the support bracket 112 can be mounted to two structural supports 120 via the fasteners 114, against a surface 122, thereby allowing a connection between an electrical device 124 and a junction box 126. Thus, the assembly 110 is configured to allow an electrical connection between the device 124 and the junction box 126 while providing a mechanical connection to the support 120.

[0081] Advantageously, assembly 110 can be used to install heavy duty electrical devices 124 without removing or replacing lightweight boxes 126 and without damaging surface 122. Rather, assembly 110 provides a mechanical connection of an electrical device 124 having heavy duty requirements to support 120 to enable the electrical device to be electrically connected to a lightweight rated junction box 126.

[0082] In the illustrated embodiment, support 120 is a ceiling joist, surface 122 is ceiling drywall, electrical device 124 is a fan, and junction box 126 is a light-grade box. Of course, the present disclosure contemplates that assembly 110 can be used with other supports 120, surfaces 122, electrical devices 124, and junction boxes 126.

[0083] Also refer to Figure 11-Figure 15 The supporting bracket 112 is described in detail.

[0084] The support bracket 112 has an outer edge 130, a main region 132, and one or more inner edges 134 (two are shown).

[0085] The outer rim 130 surrounds the main region 132 and is offset from the main region along the axis A by a first distance 136. The inner rim 134 is surrounded by the main region 132 and is offset from the main region along the axis A by a second distance 138.

[0086] The main area 132 includes a plurality of windows 140 that are sized and positioned to at least partially overlap the opening 122-1 in the surface 122. In the illustrated embodiment, the windows 140 are configured in the form of knockout holes. Thus, a user can adjust the bracket 112 by removing the knockout hole from one of the windows 140 to form a path for the electrical leads 142 of the electrical device 124 to pass to the junction box 126 - wherein the window at least partially overlaps the opening 122-1.

[0087] The outer edge 130 includes an end 144 having a first aperture 146 configured to receive a fastener 114 to secure the bracket 112 to the support 120. In the illustrated embodiment, each end 144 includes two first apertures 146 such that the bracket 112 is secured to the support 120 by four fasteners 114. Of course, the present disclosure contemplates that the assembly 110 has any desired number of fasteners 114 and first apertures 146.

[0088] The assembly 110 may have any length that satisfies the center-to-center distance (D) of each support 120 to which the assembly is mounted. In short, the first opening 146 preferably has a center-to-center distance (D) selected from the group consisting of 12 inches, 16 inches, 24 inches, and other desired sizes.

[0089] In some embodiments, the bracket 112 may include one or more ground terminals 118 for grounding the bracket 112, the electrical device 124, and the electrical lead 142 in a known manner. In the illustrated embodiment, the terminal 118 is shown as an example on the inner edge 134. Of course, the present disclosure contemplates that the terminal 118 is formed on any portion of the bracket 112.

[0090] The inner edge 134 is configured to secure the electrical device 124 to the bracket 112. In some embodiments, the inner edge 134 further includes a second opening 156 configured to be connected to the electrical device 124. Fig.12 , shows an exemplary connection between a portion of an electrical device 124 in the form of a fan support ball 124 - 1 having leads 142 and the assembly 110 .

[0091] The fan support ball end 124-1 is typically supported in a receiver 124-2, as is known from the applicant's own U.S. Patent No. 9,371,962. Fig.12 As shown, the receiver 124 - 2 may be secured to the support bracket 112 at the second opening 156 of the inner rim 134 using one or more second fasteners 158 .

[0092] In some embodiments, the bracket 112 is preferably formed as a single piece - but it is contemplated that the bracket is formed from multiple sections. The support bracket 112 can be made of any material having sufficient strength for the intended heavy-duty application. For example, the bracket 112 can be formed from metal and / or polymers. The bracket 112 can be formed by molding, stamping, casting, drawing, and other known processes. In a specific example, the bracket 112 is formed from a single piece of galvanized steel that is stamped, drawn, or molded.

[0093] Although not shown with respect to the bracket 112, the present disclosure contemplates that the bracket 112 is configured such that the outer edge 130 extends into the main region 132, defining ears on opposite sides of the portion of the outer edge having the first opening 146 in the manner described above with respect to the bracket 12.

[0094] In some embodiments, the bracket 112 may include one or more arms 148 configured to receive a cable tie or other cable management device for securing the electrical leads 142 .

[0095] In some embodiments, assembly 110 may further include a decorative cover 116 that conceals or otherwise provides a decorative appearance to the assembly. Fig.15 A cover 116 is depicted. The cover 116 may be in the form of a decorative medallion as is known in the art. The cover 116 is removably attachable to the support bracket 112 and is sized and configured to conceal the support bracket 112 when attached except for a portion that is attachable to and shielded by the electrical device 124.

[0096] The cover 116 has an outer periphery 164 , an interior cavity 166 , a second window 168 , and one or more connectors 170 .

[0097] The perimeter 164 is larger than the outer dimensions of the stent 112. The cavity 166 has a sufficient volume to receive the stent 112 therein.

[0098] The second window 168 is sized so that when the cover 116 is removably connected to the bracket 112, the inner edge 134 of the bracket extends into the cover at the second window - and in some embodiments beyond the outer surface of the cover.

[0099] The connector 170 can be removably connected to a corresponding connector (not shown) defined on the bracket 112. In the illustrated embodiment, the connector 170 is shown as a push pin received in an opening of the bracket. Of course, the present disclosure contemplates that the cover 116 is removably connected to the bracket 112 in any desired manner.

[0100] In some embodiments, the assembly 110 can include a cover plate 128 positioned on the bracket 112 (such as on the outer edge 130). When the decorative cover 116 is present, the cover plate 128 is between the bracket 112 and the cover. The plate 126 can be fixed to the bracket 112 so that the space defined between the cover plate 128 and the main area 132 defines a conduit or junction box for the passage of electrical leads 142 from the electrical device 124 and the junction box 126.

[0101] In an embodiment having a cover plate 128, the connector 170 of the trim cover 116 is removably connected to a corresponding connector 172 defined on the cover plate 128. In the illustrated embodiment, the connector 170 is shown as a push pin and the connector 172 is shown as a third opening.

[0102] When installed, the cover 116 can conceal the bracket 112 so that the bottom edge 174 of the cover is in contact with the surface 122. In some embodiments, the connectors 170, 172 can provide a biasing force to keep the edge 174 in contact with the surface.

[0103] The cover 116 can be formed of metal and / or polymer. The cover 116 can be formed by molding, stamping, casting, drawing and other known processes. In a specific example, the cover 116 is formed of a single piece of molded insulating material, such as but not limited to plastic, polyurethane and other materials.

[0104] Typically, bracket 112 is configured to be mounted to support 120 in an opposite position relative to bracket 12. In other words, bracket 12 is configured to form a space between the bracket and surface 22 for routing electrical leads 42 and - in some embodiments - include cover 28 to prevent contact between the leads and the surface.

[0105] In contrast, the bracket 112 is configured to form a space between the bracket and the trim cover 116 for routing the electrical leads 142 and—in some embodiments—includes a cover 128 to prevent contact between the leads and the trim cover 116 .

[0106] Reference now Fig.16 , another alternative exemplary embodiment of a bracket 212 for use with the assembly 110 .

[0107] Bracket 212 is particularly configured to support an electrical device in the form of a ceiling fan having a fan support ball end. Here, bracket 212 includes an inner edge 234 configured to receive a fan ball receptacle of the ball end. In some embodiments, inner edge 234 may further include an opening 256 for affixing an electrical device other than a ceiling fan.

[0108] Now refer to Figure 17-Figure 22 , another alternative exemplary embodiment of a surface mount support assembly according to the present disclosure is shown and generally indicated by the reference numeral 310 .

[0109] Assembly 310 includes support bracket 312 and, in some embodiments, one or more fasteners 314, decorative cover 316, and / or one or more ground terminals 318. Assembly 310 is configured such that support bracket 312 can be mounted to two structural supports 320 via fasteners 314, against surface 322, to allow connection between electrical device 324 and junction box 326. Thus, assembly 310 is configured to allow electrical connection between device 324 and junction box 326 while providing a mechanical connection to support 320.

[0110] Advantageously, assembly 310 can be used to install heavy duty electrical devices 324 without removing or replacing lightweight boxes 326 and without damaging surface 322. Rather, assembly 310 provides a mechanical connection of an electrical device 324 having heavy duty requirements to support 320 to enable the electrical device to be electrically connected to a lightweight rated junction box 326.

[0111] In the illustrated embodiment, support 320 is a ceiling joist, surface 322 is ceiling drywall, electrical device 324 is a fan, and junction box 326 is a light-grade box. Of course, the present disclosure contemplates that assembly 310 can be used with other supports 320, surfaces 322, electrical devices 324, and junction boxes 326.

[0112] The bracket 312 has an outer edge 330 , a main region 332 , and an inner region 334 .

[0113] The outer rim 330 surrounds the main region 332 and is offset from the main region by a first distance 336 along the axis A. The main region 332 surrounds the inner region 334 and is offset from the inner region by a second distance 338 along the axis A.

[0114] The main area 332 includes a plurality of windows 340, wherein the windows are sized and positioned such that at least one window can at least partially overlap with the opening 322-1 in the surface 322. In the illustrated embodiment, the windows 340 are configured in the form of knockout holes. Thus, a user can adjust the bracket 312 by removing the knockout hole from one of the windows 340 to form a path for electrical leads (not shown) of the electrical device 324 to pass to the junction box 326 - wherein the window at least partially overlaps with the opening 322-1.

[0115] The main region 332 includes a first aperture 346 configured to receive a fastener 314 to secure the bracket 312 to the support 320. In the illustrated embodiment, each end of the main region 332 includes two first apertures 346, such that the bracket 312 is secured to the support 320 by four fasteners 314. Of course, the present disclosure contemplates that the assembly 310 has any desired number of fasteners 314 and first apertures 346.

[0116] The assembly 310 can have any length that satisfies the center-to-center distance (D) of each support member 320 to which the assembly is mounted. In short, the first opening 346 preferably has a center-to-center distance (D) selected from the group consisting of 12 inches, 16 inches, 24 inches, and other desired sizes.

[0117] In some embodiments, the bracket 312 may include one or more grounding terminals 318 for grounding the bracket, the electrical device 324, and the electrical leads (not shown) in a known manner. In the illustrated embodiment, the terminal 318 is shown as an example on the inner area 334. Of course, the present disclosure contemplates that the terminal 318 is formed on any portion of the bracket 312.

[0118] The inner region 334 is configured to secure the electrical device 324 to the bracket 312. Here, the inner region 334 further includes a second opening 356 configured to be connected to the electrical device 324.

[0119] In the illustrated embodiment, the interior region 334 is configured as a generally x-shaped structure with ground terminals 318 and second openings 356 on alternating legs of the x-shaped structure. Without wishing to be bound by any particular theory, the interior region 334 is elevated a second distance 338 along the axis A relative to the main region 332 in conjunction with the x-shaped structure, which is believed to provide the interior region with increased resistance to bending in the range of the second opening 356. Of course, the present disclosure contemplates additional rigidity-enhancing configurations for the interior region 334.

[0120] In some embodiments, the bracket 312 is preferably formed as a single piece - but it is contemplated that the bracket is formed from multiple sections. The support bracket 312 can be made of any material having sufficient strength for the planned heavy-duty application. For example, the bracket 312 can be formed from metal and / or polymers. The bracket 312 can be formed by molding, stamping, casting, drawing, and other known processes. In a specific example, the bracket 312 is formed from a single piece of galvanized steel that is stamped, drawn, or molded.

[0121] In some embodiments, bracket 312 may include one or more arms 348 configured to receive electrical leads (not shown) for securing electrical device 324 as the leads pass from interior region 334 to window 340 .

[0122] Reference Fig. 20 An exemplary connection between a portion of an electrical device 324 and a bracket 312 is shown, the electrical device 324 being shown as a fan. Here, the electrical device 324 has a fan support ball 324-1 attached to a fan rod 324-3, a ball cover 324-4, and a ball connector 324-5. During installation, the connector 324-5 is first secured to the interior region 334 at the second opening 356 by a fastener (not shown). Next, the fan rod 324-2 is inserted through the opening in the ball cover 324-4 so that the fan support ball 324-1 is retained in the cover. Finally, the ball cover 324-4 is secured to the connector 324-5 by a fastener 324-6.

[0123] As is known from applicant's own U.S. Patent No. 9,371,962, it is known to support the fan support ball head end 324-1 in a receiver (not shown). Therefore, in some embodiments, the connection member 324-5 can be a prior art receiver so that the ball head cover member 324-4 is not a load-bearing member, but only shields or covers the connection. It should be recognized that in this embodiment, similar to Fig.12 As shown, the connecting member 324-5 is separated from the bracket 312 and connected to the bracket. However, for the receiver embodiment, it is also possible to cancel the connecting member 324-5 and form a similar Fig.16 A receiver is shown integral to interior region 334.

[0124] In some embodiments, assembly 310 can include a cover plate 328 positioned on bracket 312 (e.g., positioned on outer edge 330). When decorative cover 316 is present, cover plate 328 is between bracket 312 and decorative cover. Cover plate 328 can be secured to bracket 312 so that the space defined between cover plate 328 and main area 332 defines a conduit or junction box for electrical leads (not shown) from electrical device 324 through window 340 into junction box 326.

[0125] In some embodiments, assembly 310 may further include a decorative cover 316 that conceals or otherwise provides a decorative appearance to the assembly. Figure 21-22 Cover 316 is described.

[0126] The cover 316 can be formed of metal and / or polymer, and can be formed by molding, stamping, casting, drawing and other known processes. In a specific example, the cover 316 is formed of a single piece of molded insulating material, such as but not limited to plastic, polyurethane and other materials.

[0127] The cover 316 may be in the form of a decorative medallion as is known in the art. The cover 316 is removably connected to the support bracket 312 and is sized and configured to conceal the support bracket 312 when connected except for a portion that is connectable to and shielded by the electrical device 324.

[0128] The cover 316 has an outer periphery 364, an inner cavity 366, and a second window 368. The cover 316 has an inwardly facing connection piece or lip 370 on the outer periphery. The cavity 366 has a volume sufficient to receive the bracket 312 therein.

[0129] The second window 368 is sized such that when the cover 316 is removably coupled to the bracket 312, the interior region 334 of the bracket is aligned with the second window and, in some embodiments, protrudes through the second window.

[0130] The lip 370 is removably connected to the outer edge 330 of the bracket 312. Specifically, the outer edge 330 defines a space between the outer edge and the surface 322 sufficient to receive the lip 370. When the cover 316 is pressed onto the bracket 312, the cover elastically flexes to allow the lip 370 to pass over the outer edge 330 and bend back to a shape in which the lip is located in the space between the outer edge 330 and the surface 322.

[0131] Of course, the present disclosure contemplates that the cover 316 is removably connected to the bracket 312 in any desired manner. For example, the cover 316 can further include a cross member 368-1 in the window 368, wherein the cross member 368-1 can secure the cover to the bracket 312. For example, when the connector 324-4 is secured to the interior region 334 at the second opening 356 by a fastener (not shown), the cross member 368-1 is sandwiched between the connector 324-1 and the bracket 312 to hold the cover 316 in place.

[0132] It should also be noted that the terms "first", "second", "third", "upper", "lower", etc. may be used herein to modify various elements. Unless specifically stated, these modifiers do not imply a spatial, sequential, or hierarchical order to the modified elements.

[0133] Although the present disclosure has been described with reference to one or more exemplary embodiments, it will be appreciated by those skilled in the art that various changes may be made and elements thereof may be replaced with equivalents without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt specific circumstances or materials to the guidance of the present disclosure without departing from the scope of the present disclosure. Therefore, it is intended that the present disclosure is not limited to the specific embodiments disclosed as the expected best mode, but that the present disclosure will include all embodiments falling within the scope of the appended claims.

[0134] Parts List

[0135] Surface mount support assembly 10, 110, 310

[0136] Support bracket 12, 112, 212, 312

[0137] One or more fasteners 14, 114, 314

[0138] Decorative cover 16, 116, 316

[0139] One or more ground terminals 18, 118, 318

[0140] Structural support 20, 120, 320

[0141] Surface 22, 122, 322

[0142] Openings 22-1, 22-2, 122-1, 322-1

[0143] Electrical devices 24, 124, 324

[0144] Fan support ball head 24-1, 124-1, 324-1 Ball head end receiver 24-2, 124-2 Terminal box 26, 126, 326

[0145] Cover 28, 128, 328

[0146] Outer edge 30, 130, 330

[0147] Main area 32, 132, 332

[0148] Internal area 34, 134, 234, 334

[0149] First distance 36, 136, 336

[0150] Axis A

[0151] Second distance 38, 138, 338

[0152] First window 40, 140, 340

[0153] Electrical leads 42, 142

[0154] End 44, 144

[0155] First opening 46, 146, 346

[0156] Center to center distance (D)

[0157] Ear 50

[0158] Wall segment 52

[0159] Second opening 56, 156, 256, 356

[0160] Second fastener 58 , 158

[0161] Wall segment 62

[0162] Peripheral 64, 164, 364

[0163] Internal cavity 66, 166, 366

[0164] Second window 68, 168, 368 one or more connectors 70, 170, 370 corresponding connectors 72, 172

[0165] Bottom edge 74, 174

[0166] Arm 348

[0167] Fan rod 324-3

[0168] Ball head cover 324-4

[0169] Connector 324-5

[0170] Fastener 324-6

[0171] Cross member 368-1

Claims

1. An electrical device support assembly for securing to a surface, comprising: a support bracket having an outer edge, a main region, an inner region, and one or more first openings configured to secure the support bracket to a pair of structural supports of the surface, Around the outer edge of the main area, The main area surrounding the inner area, and An interior region includes one or more second openings configured for mechanically connecting the electrical device to the support bracket.

2. The assembly according to claim 1, wherein The one or more first openings are located in the outer edge or main region.

3. The assembly according to claim 1, wherein: The inner region has a first window through which electrical leads of the electrical device can pass.

4. The assembly according to claim 1, wherein: The main area includes a plurality of first windows through which electrical leads of the electrical device can pass.

5. The assembly according to claim 4, wherein: The plurality of first windows include a plurality of knockout holes.

6. The assembly according to claim 1, wherein: The outer edge is offset from the main region by a first distance along the axis, and the main region is offset from the inner region by a second distance along the axis.

7. The assembly according to claim 6, wherein: The first distance provides a space through which electrical leads can pass.

8. The assembly of claim 7, further comprising a cover plate positioned on the outer edge such that an enclosed space is defined in the support bracket.

9. The assembly according to claim 8, wherein: The cover is between the surface and the support bracket, or the bracket is between the surface and the cover.

10. The assembly of claim 1, wherein: The center-to-center distance of the first openings is equal to the center-to-center distance (D) of the pair of structural supports.

11. The assembly according to claim 1, wherein: The support bracket is configured such that the outer edge extends into the main block to define ears on opposite sides of a portion of the outer edge having the at least one first opening.

12. The assembly of claim 1, wherein: The support bracket is formed as a single piece of galvanized steel.

13. The assembly of claim 1, further comprising a decorative cover, wherein: A decorative cover is sized to conceal the support bracket and has a second window sized and positioned to align with an interior region of the support bracket when the cover is removably connected to the support bracket.

14. The assembly of claim 13, wherein: The decorative cover includes an integrally formed connector that is removably connectable to the support bracket.

15. An electrical device support assembly for securing to a surface, comprising: a support bracket having an outer rim, a main region, and an inner region, the outer rim surrounding the main region, and the main region surrounding the inner region; at least two first openings in the primary region, the first openings being configured to secure the support bracket to a pair of structural supports of the surface, the at least two first openings having a center-to-center distance equal to a center-to-center distance (D) of the pair of structural supports; a first distance that offsets the outer edge from the main region in a first direction; at least two second openings in the primary region, the second openings being configured for mechanical connection of the electrical device to the support bracket; a ground terminal in the main region, the ground terminal being configured for a ground connection of the electrical device; a cover plate on the outer edge so that an enclosed space is defined in the support bracket, the enclosed space being defined by the first distance between a main area of ​​the bracket abutting against the surface and the cover; as well as A plurality of knockout holes in the main area through which electrical leads of the electrical device can pass.

16. The assembly of claim 15, wherein: The support bracket is formed as a single piece of galvanized steel.

17. The assembly of claim 15, further comprising a second distance offset from the main region to the inner region in the first direction.

18. The assembly of claim 17, wherein: The main region is configured as an x-shaped structure having ground terminals and at least two second openings on alternating legs of the x-shaped structure.

19. The assembly of claim 15, further comprising a decorative cover, wherein: A decorative cover is sized to conceal the support bracket and has a second window sized and positioned to align with an interior region of the support bracket when the cover is removably connected to the support bracket.

20. The assembly of claim 19, wherein: The trim cover includes an integrally formed lip that is removably connectable to an outer edge of the support bracket.

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