Ceiling box installation assembly

Abstract

The present invention provides a ceiling box installation assembly (100) to secure electrical fixtures suspended from a ceiling (146). The ceiling box installation assembly (100) comprises a ceiling junction box (102), at least a pair of oppositely disposed grooved cuts (110) and a fixing assembly (116). The fixing assembly (116) comprises: at least a pair of claw fasteners (118), at least a pair of claw members (120), and at least a pair of mounting brackets (124). The mounted brackets (124) comprise a first opening (126) to receive said claw fasteners (118), and a second opening (128) disposed adjacent to said first opening (126) to hang said electrical fixture. The mounted brackets are fitted with said claw fasteners (118) disposed at a proximal end (112) of said grooved cuts (110) to hang said electrical fixture and transferring its weight to said claw members (120).

Description

Field of invention:The present invention generally relates to installation of electrical outlet boxes on the ceilingto accommodate different electrical equipment such as lighting fixtures to hang therefrom.More particularly, the present invention relates to improvement in installation of ceilingjunction boxes by transfer and redistribution of weights from the electrical devices.Background of the invention:Electrical equipment such as lighting fixtures, fans and the like are typically installed bymounting them directly to a ceiling junction box, or a junction box in general. Junction boxes,based on their uses and user requirements, are in general installed within a wall, ceiling, orother surface. Conventionally, junction box includes compartment having an opening at itsfront portion with mounting tabs projecting across the open front. The mounting tabs includethreaded openings for accepting screws or bolts for mounting a fixture, cover plate etc.In many installation practices, the junction box is installed in a recessed fashion within thesurface to provide a flush mount of the fixture against the surface while complying withvarious industry standards, including standard dimensions and locations for attaching a fixtureto the junction box. In buildings having concrete or wooden ceilings and walls, there aredifferent problems involved in attaching electric wiring and interior fittings. In such ceiling,the positioning of outlet boxes and similar fittings must be decided in advance and cannot bechanged subsequently thus the fixtures has to be certainly pre-located. Also the interiorfittings have to be attached to mounting means embedded in the concrete in connection withthe concrete at fixed places. Typically, installation of the junction box and electrical fixturesare carried out by a licensed electrician. In many cases, the step of mounting a fixture to thejunction box is a time-consuming process requiring forming individual connections ofmultiple wires, followed by fastening the fixtures to the junction boxes.Further, various considerations are necessary in providing holding support to the electricalequipment and fixtures for ceiling-mounted junction boxes. There exists specific maximumlimit weight for ceiling light fixtures, ceiling fans etc. Thus it becomes very important that aninstaller use adequate load-bearing fasteners for securing the junction box with beams of theceiling such that the weight if the fixtures are taken care of. It is also important that the loadbe transferred to the beams, and not by the junction box. In a known process of installation, auser has to install a ceiling fixture to the assembly, the installer first affixes the ceiling box tothe adjustable mounting brace through the elongated screw holes on the bottom of the ceilingbox. Then the installer affixes the ceiling fixture by aligning screw holes on the slider withthe screw holes on the ceiling box flange and screw tabs using screws.In one such conventional mounting practice of mounting ceiling junction box (102') andelectrical fixtures (148') is depicted in figures 1A and 1B. The claw members (120') of thejunction box have to be fixed prior to the installation of the fixture (148'). Next, the outlet forthe electrical fixture (148') is screwed with the junction box (102') in such a manner that theclaw members (120') only partially bears the weight of the fixture. Since there is nointerlinking between the claw member (120') and fixing screw (118') of the electrical fixture(148'), a substantial amount of weight has to be sustained by the junction box (102') itself.And so, there is a need for improvement in the presently available installation system tomitigate the below shortcomings:- non-metallic ceiling boxes cannot bear the suspension load, leading to deformation andbreakage or crack in the ceiling box;- existing ceiling boxes cannot be mounted front (of ceiling), to be used in retro fits orrenovation- front mounted ceiling does not have access to celling structure to transfer the suspensionload.With a view therefore to overcome the drawbacks associated with conventional systems andmethod of mounting and installation of ceiling boxes, the inventors devised a novel ceilingbox mounting assembly. In the present installation assembly, the complete celling structurecan be made and then the hole can be drilled from the outside the thereupon the ceiling boxcan be mounted. Further, the present invention provides an improved fixing mechanism thatre-directs the weights of the hanging fixtures to the beams of the ceiling rather than puttingweight on the junction box.Summary of the invention:Accordingly, the present invention provides a ceiling box installation assembly to secureelectrical fixtures suspended from a ceiling, wherein said ceiling box installation assemblycomprising:- a ceiling junction box having a front portion, a base portion, and side walls connected withsaid front portion and base portion;- at least a pair of grooved cuts extending along outer surface of said side walls, having aproximal end and a distal end; and- a fixing assembly attached with ceiling junction box to adjustably fix said electrical fixturethereon, said fixing assembly comprises:- at least a pair of claw fasteners disposed through said proximal end of said groovedcut towards said base portion;- at least a pair of claw members disposed on each of the distal end of said groovedcuts, wherein each of said claw members comprises a fixing hole through which saidclaw member is rotatably attached with corresponding claw fastener; and- at least a pair of mounting brackets disposed at the proximal end of said groovedcuts, each of said mounting brackets is fitted with said claw fasteners to hang saidelectrical fixture and transferring its weight to said claw members via said fasteners,wherein said mounting brackets comprise:- a first opening to receive said claw fasteners, and- a second opening disposed adjacent to said first opening to hang saidelectrical fixture.According to one embodiment of the invention, said proximal end of the grooved cuts aredisposed behind said front portion of said ceiling junction box, defining a step at said side wallsto rest one flat head of said claw fasteners, and said distal end is disposed on said base portionof said ceiling junction box.According to one embodiment of the invention, said ceiling junction box comprises a firstreceiving hole disposed on said proximal end of said grooved cut and a second receiving holedisposed on said base portion to receive said claw fastener in a guided manner.According to one embodiment of the invention, said base portion of said junction box isprovided with a claw recesses to accommodate said claw members whereby while mountingsaid junction box, said claw members are rotated out of said claw recesses.According to one embodiment of the invention, each of said fixing hole of said claw memberhas a matching profile to that of said first opening of said mounting bracket to firmly guide theclaw fasteners.According to one embodiment of the invention, said ceiling junction box is provided with acollar disposed around said front portion extending therefrom.According to one embodiment of the invention, said grooved cuts are disposed at opposite ordiametrically opposite faces of said side wall of said celling junction box.According to one embodiment of the invention, the base portion is provided with plurality ofremovable strain relief knock-offs for receiving corresponding electrical wire and conduits.According to another embodiment of the invention, said mounting bracket is one flat bracketattached to said base portion of said ceiling junction box to mount with the ceiling, said flatbracket having at least one pair of receiving caps to receive said corresponding claw fastener.According to another embodiment of the invention, said flat bracket has a rectangular profilehaving said receiving caps disposed at its opposite corners and another pair of mounting holesto receive mounting screws to attach said flat bracket with said base portion of said ceilingjunction box.According to another embodiment of the invention, said fixing assembly comprises a pair ofthreaded bush with rivets to receive corresponding pair of claw fasteners.Brief description of the drawings:Figures 1A-1B depict cut away view of a conventional installation of ceiling box installed ina hollow wall in ceiling applicationFigure 2 depicts an assembled perspective view of the invented ceiling box installationassembly according to one embodiment of the invention.Figure 3 illustrates an exploded view of the invented ceiling box installation assemblyaccording to one embodiment of the invention.Figure 4 is a cut away sectional view of the installation of invented ceiling box installationassembly, installed to a plaster board or main ceiling.Figure 5 is cut away cross-sectional view of the engagement fastening members of the ceilingbox installation assembly.Figure 6 illustrates another exploded view of the ceiling box installation assembly providedwith mounting brackets disposed at its base portion.Figure 7 is an assembled view of figure 6.Figures 8 and 9 depict sectional view of the ceiling box installation assembly, showing thefixing assembly according to one embodiment of the invention.Detailed description of the drawings:In the following, numerous specific details are set forth to provide a thorough description ofembodiment. Those skilled in the art will recognize and appreciate that, despite of the detailednature of the exemplary embodiment provided herein; changes and modifications may beapplied to said embodiment without limiting or departing from the generally intended scope.Figures 2 and 3 depict an assembled and an exploded perspective view of an embodiment ofinvented ceiling box installation assembly (100). The ceiling box installation assembly (100)comprises a ceiling junction box (102), at least a pair of grooved cuts (110), and a fixingassembly (116). The ceiling box installation assembly (100) allows electricians to securelysuspend electrical fixtures from a ceiling (146) in such a manner that the weight of the electricalfixture is not prevailing on said ceiling junction box (102). The electrical fixtures includevarious types of lights, chandeliers, fans, sound systems etc., which are fixed with said ceilingjunction box (102) by means of said fixing assembly (116).The ceiling junction box (102), as shown in figure 3, has a front portion (104), a base portion(106), and side walls (108) connecting said front portion (104) and base portion (106). Theceiling junction box, also referred as junction box (102) for brevity, is provided with a collar(138) disposed around said front portion (104) extending therefrom. According the presentembodiment, the junction box (102) can have a tubular side wall (108) with circular frontportion (104) defining the opening to receive said electrical fixture. For manufacturingpurposes, and based on the type of electrical fixture, the junction box (102) can be a rectangularone while keeping the disposition and functionality said fixing assembly (116) and said groovedcuts (110). The grooved cuts (110) are disposed as opposite pair of surfaces of the side walls(108) of said junction box. For a junction box (102) having tubular side wall (108), the groovedcuts (110) are provided on two diametrically opposite position of the side wall (108). Pluralityof grooved cuts (110) may also be disposed in a spaced apart manner.Each of grooved cuts (110) has a proximal end (112) and a distal end (114). The proximal end(112) is preferably disposed just behind the front portion (104) of the junction box (102) andthe distal end (114) is disposed on the base portion (106). The base portion (106) includes a flatsurface where said distal end (114) of the grooved cuts (110) finishes. The base portion (106)further includes inclined surfaces, where both the flat surface and the inclined surfaces areprovided with plurality of removable strain relief knock-offs (140). The strain relief knock-offs(140) are initially fixed with the base portion (106), which can be removed for receivingcorresponding electrical wire and conduits to be attached with the electrical fixture.With reference to figure 3, the fixing assembly (116) is attached with ceiling junction box (102)to adjustably fix said electrical fixture thereon. In the present embodiment, the fixing assembly(116) comprises a pair of claw fasteners (118), a pair of claw members (120), and a pair ofmounting brackets (124). These components can be increased in number which are disposedadjacent to each other. The claw fasteners (118) are disposed along the extension of saidgrooved cuts (110) and therefore the number of claw fasteners (118), claw members (120), andmounting brackets (124) shall correspond to the number of grooved cuts (110) disposed on theside wall (108) of the junction box (102).As shown in figures 4 and 5, the claw fastener (118) is inserted through the proximal end (112)of the grooved cuts (110) along the distal end (114) such that it touches the base portion (106)of the junction box (102). The claw members (120) are disposed on each of the distal end (114)close to the base portion (106) of the junction box. The claw members (120), at its proximalpart is provided with a fixing hole (122), by means of which it is rotatably attached with thecorresponding claw fastener (118). The base portion (106) of said junction box (102) is providedwith a pair of claw recesses (136) to accommodate said claw members (120) whereby whilemounting said junction box (102), said claw members (120) are rotated out of said claw recesses(136).With reference to figures 3 to 5 of the accompanying drawings, the proximal end (112) of thegrooved cut that defines a step (130) at said side walls (108), allows to rest one flat head of saidclaw fasteners (118). The pair of mounting brackets (124) are fitted with said claw fasteners(118) disposed each of the proximal end (112) of said grooved cuts (110). The mountingbrackets (124) facilitate the hanging of said electrical fixture by transferring its weight to saidclaw members (120). On said step (130) of the proximal end (112), a first receiving hole (132)is disposed. The first receiving hole (132) facilitates the insertion of the claw fasteners (118).Further, a second receiving hole (134) is disposed on said base portion (106) to receive saidclaw fastener (118) in a guided manner.The mounting bracket (124) is provided with a first opening (126) to receive said claw fasteners(118), and a second opening (128) to hang said electrical fixture. The mounting bracket (124)when placed on the proximal end (112) of the grooved cut (110), its first opening (126) issuperimposed with said first receiving hole (132) on the step (130). Similarly the fixing hole(122) on said claw member (120) is superimposed with second receiving hole (134) on the baseportion (106). Further, fixing hole (122) of said claw member (120) has a matching profile tothat of said first opening (126) of said mounting bracket (124) to firmly guide the claw fasteners(118). The second opening (128) of the mounting bracket (124) is disposed adjacent to the firstopening (126) based on the size of the junction box (102).Accordingly, with reference to figure 3 to 5, each of the claw fastener (118) is coupled with themounting bracket (124) at one end and the claw member (120) at other end. The claw member(120) is thus rotatably fixed with the claw fastener (118) while being connected to the secondreceiving hole (134) at the distal end (114), on said base portion (106) of said ceiling junctionbox (102). Thus, with the present ceiling box installation assembly (100), when an electricalfixture is attached using the second opening (128) at the mounting bracket (124), the weight ofthe fixture falls on the claw fasteners (118) through first opening (126) of the mounting bracket(124). The claw fasteners (118), being coupled to the claw members (120), the weight is finallytraversed to the claw member (120) rather than the junction box (102).Further, with reference to figures 6 to 9 of the accompanying drawings, the fixing assembly(116) comprises at least one mounting bracket (124) being one flat bracket (142). The flatbracket (142), according to the preferred embodiment, has a rectangular profile, being attachedto said base portion (106 ) providing additional support to mount with the junction box (102).Further, the flat bracket (142) is provided at least one pair of receiving caps (144) at one of itsdiametrically opposite corners and a pair of mounting holes (150) at other corners. In thisparticular embodiment, the fixing assembly (116) comprises a pair of threaded bush (152) withrivets to receive corresponding pair of claw fasteners (118). The receiving caps (144) are formedto receive one end of said corresponding claw fasteners (118) and mounting holes (150) toreceive mounting screws to attach said flat bracket (142) to said base portion (106) of saidceiling junction box (102). As seen in figure 7, the threaded bush (152) can be attached with thereceiving caps (144) of the flat bracket (142), where the claw members (120) are disposed justbelow said receiving caps (144) resting on said claw recess (136).As already mentioned, the foregoing description is illustrative of the invention and notlimitative to its scope, because it will be apparent to persons skilled in the art to devise otheralternative embodiments without departing from the broad ambit of the disclosures madeherein.Part-List:Ceiling box installation assembly 100Ceiling junction box 102 Front portion 104Base portion 106Side walls 108 Grooved cuts 110 Proximal end 112Distal end 114Fixing assembly 116Claw fasteners 118Claw members 120Fixing hole (of claw member) 122Mounting brackets 124First opening 126Second opening 128Step (at the proximal end) 130First receiving hole 132Second receiving hole 134Claw recesses 136Collar 138Strain relief knock-offs 140Flat bracket 142Receiving caps (on flat bracket) 144Ceiling 146Mounting hole 150Threaded bush 152

Claims

1. A ceiling box installation assembly (100) to secure an electrical fixture suspended from a ceiling (146), said ceiling box installation assembly (100) comprising: - a ceiling junction box (102) having a front portion (104), a base portion (106), and side walls (108) connected with said front portion (104) and said base portion (106); - at least a pair of grooved cuts (110) extending along outer surface of said side walls (108), said grooved cuts (110) having a proximal end (112) and a distal end (114); and - a fixing assembly (116) attached with ceiling junction box (102) to adjustably fix said electrical fixture thereon, said fixing assembly (116) comprises: - at least a pair of claw fasteners (118) disposed between said proximal end (112) of said grooved cuts (110) and said base portion (106); - at least a pair of claw members (120) disposed on the distal end (114) of each of said grooved cuts (110), wherein each of said claw members (120) comprises a fixing hole (122) through which said claw member (120) is rotatably attached with corresponding claw fastener (118); and - at least a pair of mounting brackets (124) disposed at each of the proximal end (112) of said grooved cuts (110), each of said mounting brackets (124) is fitted with said claw fasteners (118) to hang said electrical fixture and transferring its weight to said claw members (120) via said fasteners (118), wherein said mounting brackets (124) comprise: - a first opening (126) to receive said claw fasteners (118), and - a second opening (128) disposed adjacent to said first opening (126) to hang said electrical fixture.

2. The ceiling box installation assembly (100) as claimed in claim 1, wherein said proximal end (112) of the grooved cuts (110) is disposed behind said front portion (104) of said ceiling junction box (102) defining a step (130) at said side walls (108) to rest one flat head of said claw fasteners (118), and said distal end (114) is disposed on said base portion (106) of said ceiling junction box (102).

3. The ceiling box installation assembly (100) as claimed in claim 1 or 2, wherein said ceiling junction box (102) comprises a first receiving hole (132) disposed on said proximal end (112) of said grooved cuts (110) and a second receiving hole (134) disposed on said base portion (106) to receive said claw fastener (118) in a guided manner.

4. The ceiling box installation assembly (100) as claimed in any of the claims 1 to 3, wherein said base portion (106) of said ceiling junction box (102) is provided with a claw recesses (136) to accommodate said claw members (120) whereby while mounting said junction box (102), said claw members (120) are rotated out of said claw recesses (136).

5. The ceiling box installation assembly (100) as claimed in any of the claims 1 to 4, wherein each of said fixing hole (122) of said claw member (120) has a matching profile to that of said first opening (126) of said mounting bracket (124) to firmly guide the claw fasteners (118).

6. The ceiling box installation assembly (100) as claimed in any of the claims 1 to 5, wherein said ceiling junction box (102) is provided with a collar (138) disposed around said front portion (104) extending therefrom.

7. The ceiling box installation assembly (100) as claimed in any of the claims 1 to 6, wherein said grooved cuts (110) are disposed at opposite or diametrically opposite faces of said side wall (108) of said celling junction box (102).

8. The ceiling box installation assembly (100) as claimed in any of the claims 1 to 7, wherein the base portion (106) is provided with plurality of removable strain relief knock-offs (140) for receiving corresponding electrical wire and conduits.

9. The ceiling box installation assembly (100) as claimed in any of the claims 1 to 8, wherein said mounting bracket (124) is one flat bracket (142) attached to said base portion (106) of said ceiling junction box (102) to mount with the ceiling, said flat bracket (142) having at least one pair of receiving caps (144) to receive corresponding claw fastener (118).

10. The ceiling box installation assembly (100) as claimed in claim 9, wherein said flat bracket (142) has a rectangular profile having said receiving caps (144) disposed at its opposite corners and another pair of mounting holes (150) to receive mounting screws to attach said flat bracket (142) with said base portion (106) of said ceiling junction box (102).

11. The ceiling box installation assembly (100) as claimed in any of the claims 1 to 10, wherein said fixing assembly (116) comprises a pair of threaded bush (152) with rivets to receive corresponding pair of claw fasteners (118).