Vacuum hose port mounting brackets and related methods

Abstract

A mounting system for a central vacuum system hose valve box operable for secure attachment to a wall stud or frame member. The system includes flanges at the front of the valve box for attachment of either the left or right side of the front of the box to a stud or frame member. An additional rear bracket is provided for attachment of the rear of the valve box to the same wall stud or frame member. These dual attachments provide a firm and secure mount of the valve box to the wall stud, thus avoiding damage or disconnection encountered by other flimsy mounts. This configuration ensures a robust and reliable connection, maintaining the operational integrity of the vacuum hose system while providing ease of installation and maintenance.

Description

FIELD OF THE INVENTION

[0001] The present invention relates generally to an outlet box system and valve assembly module for a central vacuum system. More particularly, the present invention provides a vacuum hose valve outlet box assembly that is operable for engagement with a wall stud or frame member at multiple locations for stable mounting.BACKGROUND OF THE INVENTION

[0002] Vacuum hose valve outlet boxes are commonly used in residential and commercial settings to provide convenient access to ports for central vacuum systems. These boxes provide locations where a user may attach a vacuum hose for communication with a central vacuum unit. Conventional vacuum hose valve outlet box systems face several challenges and limitations. A significant issue is the complexity and inefficiency of the mounting process. Traditional systems typically require extensive manual effort to secure a valve box to a wall stud or frame member, involving multiple fasteners and the precise alignment of multiple brackets and face plates. Because of the small size of the valve box and the wide spacing between wall studs or frame members, typically only one side of the valve box is attached to the wall stud or frame member. This is usually accomplished by attaching a flange on one side (or the other side) of the front of the valve box to the front of a wall stud, such that the flange is flush against the front surface of the wall stud. Even when multiple fasteners are used to engage the flange with the wall stud, this can be a flimsy mount that is subject to detachment. Repair or replacement of installed outlet boxes can often require the removal of the interior wall finish to access the wall stud or frame member to which the box is mounted, which can lead to increased labor costs, and longer installation times.

[0003] Existing valve box designs often lack robust mechanisms for ensuring the stability and durability of the mounted system. Over time, the repeated attachment and detachment of a vacuum hose can cause the valve box to loosen or misalign, compromising the integrity of the installation. This can result in reduced performance of the vacuum system, disruption of vacuum or electrical connections, and potential damage to the wall structure. Another shortcoming of current systems is the limited accessibility and flexibility during installation. In many cases, installers face difficulties in aligning and securing the valve box and its components, particularly in tight or hard-to-reach spaces. This is further exacerbated by the need for precise positioning to ensure proper sealing and functionality of the valve box. Additionally, the design of conventional valve box systems often does not accommodate variations in wall stud configurations and dimensions. This lack of adaptability can necessitate custom modifications, adding to the complexity and cost of installation.

[0004] Overall, existing vacuum valve boxes suffer from the drawback of insubstantial and unsound mounting structures leading to performance problems and potential damages to wall structures, and from the drawback of an installation process that is not user-friendly and demands a high level of skill and precision, deterring potential users due to its complexity and the risk of installation errors. There is a clear need for a more sturdy, streamlined, adaptable, and efficient mounting apparatus and installation method for valve boxes of central vacuum systems.SUMMARY OF THE INVENTION

[0005] The present invention provides an improved vacuum hose valve outlet box mounting system and method that addresses the limitations and challenges of conventional systems. This innovative system simplifies the installation process, enhances the stability and durability of the mounted unit, and offers greater flexibility and adaptability to various wall stud configurations. A streamlined mounting method is provided and may significantly reduce the complexity and inefficiency associated with traditional systems.

[0006] The present invention provides an outlet box having a plurality of flanges at the corners of the box and a novel additional bracket with features that engage with a rear surface of the outlet box. The outlet box flanges and the additional bracket have through holes that are operable to receive fasteners for laterally and longitudinally attaching the outlet box to a wall studs or frame member with ease. In some embodiments, the bracket design may have a T-shaped body with flange members and through holes for receiving fasteners. In some embodiments, the interior surface of the bracket may feature snap tabs that engage with receiving apertures on the valve box, enabling a quick and secure lateral attachment to a wall stud or frame member. Embodiments of the present invention reduce the need for precise alignment and minimizes the risk of installation errors.

[0007] Embodiments of the valve box of the present invention are operable to house a suction port of a central vacuum system and securely attach it to a wall. Embodiments of the valve box include a side surface at the front of the valve box featuring a pair of flanges positioned at the corners, facilitating side attachment to a wall stud. Embodiments of the valve box may include a plurality of boreholes for securing a door assembly and compressing a sealing member, the sealing member being operable to allow for mounting and sealing to interior surface finishes of varying thickness. Embodiments of the valve box may have a symmetrical design that allows for securing to a wall studs or frame on either the right or left side of the valve box, ensuring versatile installation options.

[0008] Embodiments of the bracket may include rear bracket comprising a T-shaped member having a horizontal body with a perpendicular flange located on at least one end of the body. One or more through holes may be provided on the flange member, and may positioned symmetrically above and below the attachment to the horizontal body. An interior surface of the horizontal body may includes snap tabs designed to engage with the receiving apertures or structures on a rear surface of the valve box. In alternative embodiments, one or more through holes may be provided on the horizontal body to receive one or more fasteners (e.g., self-tapping screws) which engage the body to the back of the valve box. In some embodiments, the back of the valve box may include openings corresponding to the through holes on the horizontal body of the bracket. When the front corners of the valve box are attached to the wall stud, and the flange of the rear bracket is fastened to the wall or stud member through the through holes, and the body member is attached to the back of the valve box, both the front and the back of the valve box are attached to the wall stud, firmly securing the valve box to the wall stud, and providing a stable and robust installation.

[0009] In some implementations of the valve box and bracket, the installation process begins before the wall board is attached to the studs or frame members. In other situations, an existing wall board must be cut out according to the dimensions of the valve box opening to reveal the stud to which the valve box will be attached. Once the stud can be accessed, the pair of flanges on a side of the valve box at the front are adjacent to the wall stud. The valve box is then longitudinally secured to the wall stud by advancing fasteners through the flange through holes. It is to be appreciated that in most cases, only flanges on either the left side or the right side of the valve box (not both sides) will be used to attach to the wall stud. Following this, the rear bracket is aligned with the valve box, ensuring the fasteners or snap tabs engage securely with the receiving features or apertures on the rear of the valve box. The body of the bracket is then fastened to the rear of the valve box, and side flange is fastened to the wall stud using additional fasteners through the designated through holes.

[0010] Optionally, the door assembly can be attached by aligning it with the valve box and securing it with fasteners through the bore holes. This step compresses the sealing member between the door assembly and the valve box, ensuring horizontal securement to the wall. If access to the door assembly side is restricted, this step can be performed as the final stage of installation.

[0011] In one aspect, an embodiment of the invention provides a support structure for a central vacuum system hose outlet box comprising a housing having an interior, an exterior, a front surface, and a rear surface; at least one first flange on a first side of said front surface, and at least one second flange on an opposite second side of said front surface wherein each of said first and second flanges is operable for engagement with a wall stud; and a bracket member comprising an elongated body operable for engagement with the rear surface of said housing and a third flange member attached at one end of said elongated body wherein said third flange is operable for engagement with said wall stud. In related aspects, each of said first and second flanges may include at least one opening operable to receive a fastener for securement to a wall stud. In related aspects, a pair of first flanges are provided at a top and a bottom of said first side of said front surface and a pair of second flanges are provided at a top and a bottom of said opposite side of said front surface. In related aspects, all of the first and second flanges are mounted perpendicularly to a plane of said front surface and are operable for engagement against a side surface of a wall stud. In other aspects, all of the first and second flanges are mounted in parallel to a plane of said front surface and are operable for engagement against a front surface of a wall stud. In some aspects, the third flange includes at least one opening operable to receive a fastener for securement to a wall stud. In some aspects, the elongated body includes at least one opening operable to receive a fastener for securement to the rear surface of said housing. In some aspects, the rear surface of the housing includes at least one opening, and the elongated body includes at least one tab that is operable to snap fit into said opening to secure said elongated body against said rear surface. In some aspects, the at least one first flange is attached to a wall stud and the at least one third flange is attached to the same wall stud. In some aspects, an end of the elongated body is attached to a center of said third flange such that the bracket has a T-shape. In other aspects an end of the elongated body is attached to an end of said third flange such that the bracket has an L-shape. In some aspects, a door assembly may be provided that is secured to an exterior surface of a wall adjacent to said stud, the door assembly having a compressible sealing member that is operable to engage with a recess on a front surface of said outlet box.

[0012] 15. In other aspects, embodiments of the invention may provide a vacuum hose outlet box assembly comprising: a valve box including a front surface, a rear surface, a pair of perpendicular flanges positioned at upper and lower corners of the front surface, and at least one bore hole on each flange; a bracket member comprising an elongated body with a flange member at an end thereof, wherein the flange member has at least one through hole therein and wherein said elongated body includes at least one snap tab thereon; at least one receiving aperture on the rear surface of the valve box configured to engage with the at least one snap tab of the bracket member; and a plurality of fasteners configured to secure the valve box and the bracket to a wall stud through the at least one bore hole in each perpendicular flange and the at least one through hole in the flange member of the bracket. In related aspects, the end of the elongated body is attached to a center of said third flange such that the bracket has a T-shape. In other aspects, the end of the elongated body is attached to an end of said third flange such that the bracket has an L-shape.

[0013] In other aspects, embodiments of the invention may provide methods of installing a central vacuum outlet box comprising the steps of: positioning a pair of flanges located along a front surface of the outlet box against a surface of a wall stud; securing the outlet box to the wall stud by advancing fasteners through at least one through hole in each flange; aligning a bracket with at least one receiving aperture on a rear surface of the outlet box, the bracket comprising an elongated body with a flange member at an end thereof forming a T-shape, wherein the flange member has at least one through hole therein and wherein said elongated body includes at least one snap tab thereon; engaging the at least one snap tab of the bracket with the at least one receiving aperture on the outlet box; and fastening the bracket to the wall stud by advancing additional fasteners through the at least one through hole in the bracket flange member. In related aspects, the pair of flanges located along a front surface of the outlet box may have an orientation that is perpendicular to a plane of said front surface. In other aspects, the pair of flanges located along a front surface of the outlet box may have an orientation that is parallel to a plane of said front surface.

[0014] In different aspects, embodiments of the present invention provide a support structure for a central vacuum system hose valve housing that may include a bracket having a first member with an interior surface, an exterior surface, a proximal end, and a distal end. The bracket features a first tab and a second tab disposed on the interior surface of the first member and a flange positioned on the distal end, with at least one fastener receiver operable to receive a fastener for securement to a wall stud. The vacuum hose valve outlet box has a front and back surface, with flanges positioned at each corner of the box and a rear engagement surface with a pair of apertures complementary to the first and second tabs. The front surface of the vacuum hose valve outlet box may be aligned with the interior surface of a wall, with a pair of flanges on the same side secured to a wall stud using a fastener. The first and second tabs are engaged with the receiving apertures and fastened through at least one fastener receiver to laterally secure the hose valve housing to the wall stud. The vacuum hose outlet box flanges may protrude from the rear surface at the top and bottom corners and extend along a peripheral side edge of the rear surface. The flanges are symmetrically distributed about a vertical plane and horizontal plane of the vacuum hose valve outlet box, with centrally positioned through holes operable to receive fasteners. The valve box may include a door assembly secured to an exterior surface of the wall, the door assembly having a compressible sealing member that engages with a recess on the front surface of the vacuum hose valve outlet box. The door assembly and vacuum hose outlet box may have a plurality of complementary boreholes that align and secure the vacuum hose outlet box and door assembly on opposite sides of the wall. The receiving apertures are symmetrically distanced from the vertical plane. The first and second tabs are snapped into the receiving apertures, and the bracket flange aligns with the vacuum hose outlet box flanges. The bracket flange includes a first and second through hole positioned equidistantly from the center of the first member.

[0015] Other aspects of the present invention provide a support structure for a vacuum cleaning system hose valve housing that may include a bracket having a first member with an interior surface, an exterior surface, a proximal end, and a distal end. The bracket may feature a first tab and a second tab disposed on the interior surface of the first member and a flange positioned on the distal end, with at least one fastener receiver operable to receive a fastener for securement to a wall stud. The vacuum hose valve outlet box may have a front surface and a back surface, with flanges positioned at each corner of the box and a rear engagement surface with a pair of apertures complementary to the first and second tabs. The front surface of the vacuum hose valve outlet box may be aligned with an interior surface of a wall, with a pair of flanges on the same side secured to a wall stud using a fastener. The first and second tabs may engage with the receiving apertures and fasten through the at least one fastener receiver to laterally secure the hose valve housing to the wall stud. The vacuum hose outlet box flanges may protrude from the rear surface at the top and bottom corners and extend along a peripheral side edge of the rear surface. The flanges may be symmetrically distributed about a vertical plane and horizontal plane of the vacuum hose valve outlet box, with centrally positioned through holes operable to receive fasteners. The valve box may further include a door assembly secured to an exterior surface of the wall, the door assembly having a compressible sealing member that may engage with a recess on the front surface of the vacuum hose valve outlet box. The door assembly and vacuum hose outlet box may have a plurality of complementary boreholes that align and secure the vacuum hose outlet box and door assembly on opposite sides of the wall. The receiving apertures may be symmetrically distanced from the vertical plane. The first and second tabs may snap into the receiving apertures, and the flange of the bracket may align with the vacuum hose valve outlet box flanges. The flange of the bracket may include a first and second through hole positioned equidistantly from the center of the first member.

[0016] Additional aspects of the present invention provide a vacuum hose valve outlet box assembly, which may include a valve box with a front surface, a rear surface, a pair of perpendicular flanges at the corners of the rear surface, and a plurality of bore holes on each flange. The assembly may also include a door assembly attached to the valve box, which may feature a hinged access door and a sealing member, with the sealing member being compressible within a recess of the valve box. A bracket with a T-shaped body and a flange member at one end of the body may also be included, where the flange member may have through holes and an interior surface with snap tabs. The valve box may be equipped with a pair of receiving apertures configured to engage with the snap tabs of the bracket, and a plurality of fasteners may be provided to secure the valve box and the bracket to a wall stud through the bore holes in the flanges and the through holes in the flange member of the bracket. The valve box may align with a wall opening on the interior surface of a wall, while the door assembly aligns with the wall opening on the exterior surface of the wall, with the sealing member compressed within the recess of the valve box. The sealing member may be compressed within the recess to adjust the distance between the valve box and the door assembly, providing an airtight seal. The pair of perpendicular flanges may align with the flange member of the bracket and be fastened to the wall, securing the valve box both longitudinally and laterally.

[0017] It is another aspect of the present invention to provide a vacuum hose valve outlet box system including a vacuum hose valve outlet box, the hose outlet box having a pair of flanges positioned at the corners of the outlet box, each flange having at least one through hole. The system may include a door assembly with a hinged access door and a sealing member, the sealing member being operable to compress within a recess of the outlet box. The outlet box may have a plurality of bore holes configured to align with corresponding bore holes on the door assembly to secure the door assembly to the outlet box. The outlet box may be positioned on an interior side of a wall, while the door assembly may be positioned on an exterior side of the wall, and both may be operable to compress the wall when secured. The system may also include a bracket with a T-shaped body and a flange member on at least one end, the flange member having a pair of through holes and an interior surface with a pair of snap tabs. The valve box may be configured with a pair of receiving apertures to engage with the snap tabs of the bracket, allowing the outlet box to be secured to a wall stud through the through holes of the flanges and the through holes of the bracket, providing both longitudinal and lateral securement to the wall stud. The flanges on the outlet box may be positioned at the top and bottom corners and extend along the peripheral side edges of the rear surface, being symmetrically distributed about a vertical plane and horizontal plane of the vacuum hose valve outlet box. Each flange may have a centrally positioned through hole to receive a fastener. The receiving apertures may be symmetrically distanced from the vertical plane, and the first and second snap tabs of the bracket may engage with the receiving apertures, aligning the flange of the bracket with the flanges of the vacuum hose valve outlet box.

[0018] Finally, it is another aspect of the present invention to provide a method of assembling a vacuum hose valve outlet box assembly, that may include the steps of: preparing a wall by ensuring that a cutout aligns with the dimensions of an opening in a vacuum hose valve outlet box; inserting the vacuum hose valve outlet box into the wall cutout, positioning a pair of flanges on the valve outlet box adjacent to a wall stud; securing the vacuum hose valve outlet box to the wall stud by advancing fasteners through the through holes in the flanges; aligning a bracket with the vacuum hose valve outlet box, the bracket having a T-shaped body with a flange member, the flange member including through holes and snap tabs on an interior surface; engaging the snap tabs of the bracket with the receiving apertures on the vacuum hose valve outlet box; fastening the bracket to the wall stud by advancing additional fasteners through the through holes in the flange member; attaching a door assembly to the vacuum hose valve outlet box, the door assembly including a hinged access door and a sealing member, wherein the sealing member is compressed within a recess of the valve outlet box, ensuring a secure and airtight connection. The flange member of the bracket may align with the flanges of the vacuum hose valve outlet box to ensure both longitudinal and lateral securement. The sealing member may be compressed within the recess to adjust the distance between the valve box and the door assembly, providing an airtight seal.

[0019] Further aspects and embodiments will be apparent to those having skill in the art from the description and disclosure provided herein.

[0020] It is therefore an object of the present invention to provide methods and apparatus for securely attaching a valve box of a central vacuum system to a wall stud or frame member.

[0021] It is also an object of the present invention to provide methods and apparatus that for securely attaching both the front and the rear of a valve box of a central vacuum system to a wall stud or frame member.

[0022] It is also an object of the present invention to provide methods and apparatus for securely attaching a valve box of a central vacuum system to a wall stud or frame member that eliminates the need for precise alignment of multiple brackets and face plates, as well as the extensive manual effort typically required.

[0023] It is another object of the present invention to provide a valve box design for a central vacuum system that includes side flanges at the front of the box and a separate bracket at the rear of the box for mounting the box to a wall stud or frame member.

[0024] It is another object of the present invention to provide a mounting system for a valve box of a central vacuum system that is sturdy and less prone to damage or dislodgement under ordinary use.

[0025] The above-described objects, advantages, and features of the invention, together with the organization and manner of operation thereof, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like elements have like numerals throughout the several drawings described herein. Further benefits and other advantages of the present invention will become readily apparent from the detailed description of the preferred embodiments.BRIEF DESCRIPTION OF THE DRAWINGS

[0026] FIG. 1 provides a rear perspective environmental view of a central vacuum valve box assembly attached to a stud member, according to an embodiment of the present invention.

[0027] FIG. 2A provides an exploded perspective view of a central vacuum valve box assembly without the wall or stud, according to an embodiment of the present invention.

[0028] FIG. 2B provides a side view of a central vacuum valve box assembly, a wall and stud, and a door assembly according to an embodiment of the present invention.

[0029] FIG. 3 provides a rear environmental perspective view of a vacuum hose port valve housing positioned against a wall and stud prior to attachment of the housing to the wall and stud, according to an embodiment of the present invention.

[0030] FIG. 4 provides a rear environmental perspective view of a hose port valve housing positioned against a wall and stud during attachment of the housing to the wall and stud, according to an embodiment of the present invention.

[0031] FIG. 5 provides a rear environmental perspective view of the hose port valve housing assembly with the front thereof secured to the stud, according to an embodiment of the present invention.

[0032] FIG. 6 provides a rear environmental perspective view of a hose port valve housing with the front attached to a stud prior to attachment of a rear bracket, according to an embodiment of the present invention.

[0033] FIG. 7 provides a rear environmental perspective view of a hose port valve housing with the front attached to a stud, and a bracket attached to the back of the housing, prior to attachment of the bracket to the stud, according to an embodiment of the present invention.

[0034] FIG. 8 provides a perspective view of an embodiment of a rear bracket of the present invention.

[0035] FIG. 9 provides a side view of the embodiment of the bracket of FIG. 8.

[0036] FIG. 10 provides a top view of the embodiment of the bracket of FIG. 8.

[0037] FIG. 11 provides a rear view of a valve box, according to an embodiment of the present invention.

[0038] FIG. 12 provides a lower perspective view of a valve box, according to an embodiment of the present invention.

[0039] FIG. 13 provides a rear view of an embodiment of a valve box and rear bracket attached to a wall stud, according to an embodiment of the present invention.

[0040] FIG. 14 provides a section view of along line A-A of FIG. 13, according to an embodiment of the present invention.

[0041] FIG. 15 provides a perspective view of an alternative embodiment of a rear bracket of the present invention.

[0042] FIG. 16 provides a side view of the embodiment of the bracket of FIG. 15.

[0043] FIG. 17 provides a top view of the embodiment of the bracket of FIG. 15.

[0044] FIG. 18 provides a perspective view of another alternative embodiment of a rear bracket of the present invention.

[0045] FIG. 19 provides a side view of the embodiment of the bracket of FIG. 18.

[0046] FIG. 20 provides a top view of the embodiment of the bracket of FIG. 18.

[0047] FIG. 21 provides a front view of an alternative embodiment of a valve box of the present invention.DETAILED DESCRIPTION

[0048] Reference will now be made in detail to certain embodiments of the invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in reference to these embodiments, it will be understood that they are not intended to limit the invention. To the contrary, the invention is intended to cover alternatives, modifications, and equivalents that are included within the spirit and scope of the invention. In the following disclosure, specific details are given to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the present invention may be practiced without all of the specific details provided.

[0049] Referring to the drawings, wherein like reference characters designate like or corresponding parts throughout the several views, and referring particularly to FIGS. 1-11, it is seen that the present invention contains various views of a vacuum hose valve outlet box system that is operable to secure to a structural members in a wall using a plurality of fasteners and a rear bracket having a plurality of features that are operable to laterally secure a hose valve outlet box system to a structural members such as a wall frame or stud member.

[0050] The present invention includes a vacuum hose valve outlet box or housing 120 that is operable to house a suction port of a central vacuum system. The outlet box 120 may couple to a wall 70 and to a door assembly 42 that includes hinged access door 71 and a sealing member 41 that is operable to compress in the recess 141 of the outlet box 120.

[0051] The illustrated embodiments of the outlet box 120 may include a front surface 130 having a pair of left side flanges 146 and a pair of right side flanges 146, all of which have an orientation that is perpendicular to surface 130. It is to be appreciated that in other embodiments, a single flange may be provided on the right and left sides of the front surface 130, and in other embodiments multiple flanges may be provided on the right and left sides of the front surface 130.

[0052] In the illustrated embodiments, each of the flanges 146 are positioned at the corners of the outlet box 120, as shown in FIGS. 1-4, and may include one or more through holes 148 that is / are operable to receive one or more fasteners 150 that is / are operable to longitudinally secure the flange 146 of the valve box 120 to a wall stud 37 on either a right side or a left side of the valve box. In the illustrations of FIGS. 4 and 5, the left side of the valve box 120 (looking from the front) is attached to wall stud 37. It is to be appreciated that in other embodiments, flanges 146 may be positioned at any location along the length of either side of surface 130 of valve box 120, that multiple flanges 146 may deployed on either side, and that different numbers of flanges 146 may be provided on one side as compared to the other side of surface 130.

[0053] In other embodiments as shown in FIG. 21, one or flanges 146 may be provided on the same plane as front surface 130, or in parallel to that plane, so that these flanges may be positioned flush against a front surface of wall stud 37. In these embodiments, a single flange 146 may be provided on each side of surface 130, or multiple flanges may be provided on each side. Also, a different number of flanges 146 may be provided on one side of surface 130 as compared to the other side. Each flange 146 may include one or more through holes 148 for receiving one or more corresponding fasteners 150 to engage the flanges 146 flush against the front surface of stud 37.

[0054] The outlet box 120 may also have a plurality of bore holes 147 that align with bore holes 142 of a door assembly 42, as shown in FIG. 2A. For attachment of the door assembly, a fastener is advanced through the bore holes 142 and bore hole 147 to compress the sealing member 41 between the door assembly 42 and the outlet box 120 and horizontally securing to a wall 70 as illustrated in the steps in FIGS. 2B and 3.

[0055] In embodiments of the invention, a rear bracket 100 is provided as shown in FIGS. 6-10. Bracket 100 may have a T-shape with a longitudinal body member 104 attached perpendicularly to a flange member 114 that is provided on at least one end of body member 104. Flange member 114 may have one or more through holes 115a, 115b that may be positioned symmetrically above and below the body member 104.

[0056] Referring to the embodiment shown in FIGS. 8-10, it is seen that the illustrated body member 104 may have an interior surface 104i that has one or more snap tabs 110a, 110b that are operable to engage with corresponding receiving apertures 127a, 127b on a rear mounting surface 125 of the valve box 120. The illustrated embodiment shows a pair of snap tabs 110a, 110b and apertures 127a, 127b, as shown in FIGS. 6, 11, and 12. To attach bracket In assembly, as illustrated in FIG. 6 the snap tabs (110a, 110b) are aligned and clipped into the receiving apertures (127a, 127b). In these embodiments, the bracket snap tab 100b may correspond to the receiving aperture 127b, and the length of the flange member 114 from the snap tab 110b may be equal to the distance of the receiving aperture 127b to the pair flanges 146 of the valve box 120, as best illustrated in FIGS. 13-14.

[0057] It is to be appreciated that in alternative embodiments, body member 104 may include one or more openings through which one or more fasteners may be inserted for engagement of the body member 104 to a rear surface 125 of the valve box 120. Any suitable fasteners may be used for this purpose including without limitation self-tapping screws and the like.

[0058] As shown in FIG. 7, once the body member 104 is attached to the rear surface of the valve box 120, a fastener 150 corresponding to each through hole 115a, 115b of flange 114 may be advanced through the through holes and into the wall stud 37, thereby firmly securing the bracket 100 to both the wall stud 37 and the back of the valve box 120.

[0059] In alternative embodiments, such as those shown in FIGS. 15-20, bracket 100 may be provided in the form of a flat member having an L-shape with a longer portion 131 operable for attachment to the back of the valve box, and a shorter portion 135 positioned orthogonally to the longer portion for attachment to the wall stud 37. In these embodiments, one or more openings 132 may be provided on the longer portion 131 to receive fasteners 133 for engagement of the longer portion to the rear surface 125 of the valve box 120. Similarly, one or more openings 136 may be provided on the shorter portion 135 to receive fasteners 137 for engagement of the shorter portion to the wall stud 37.

[0060] It is to be appreciated that the valve box 120 is generally symmetrical such that valve box 120 may be secured to a wall stud 47 using the flanges 146 provided on either the left side 120L or the right side 120R of the valve box 120, using the same steps described and illustrated above. Similarly, bracket 100 flange member 114 is operable to be positioned adjacent to either the left side 120L or the right side 120R of the valve box, for attachment to the same wall stud member 37 as flanges 146.

[0061] To install an embodiment of a valve box of the present invention, access to a wall support stud 37 is first required. This may be accomplished during new construction before the wall panels 70 are installed, or afterwards by cutting out a section of the wall panel 70. Then, a valve box 120 of the present invention is positioned such that a pair of flanges 146 on either the right side or the left side of the valve box is adjacent to the wall stud 37. Valve box 120 may be secured to the wall stud 37 by advancing fasteners150 through the through holes 148 of side flanges 146, ensuring the box is longitudinally secured. Next, a bracket 100 is aligned with and attached to the back of the valve box 120. In some embodiments, this may be accomplished by engaging snap tabs 110a, 110b with the apertures 127a, 127b on rear surface 125 of the valve box. In other embodiments, this is accomplished by inserting one or more fasteners through openings in bracket body 104 to engage body 104 to the back 125 of the valve box 120; or inserting fasteners 133 into openings 132 of the longer portion 131 of the L-shaped version of the bracket. Finally, flange 114 of bracket 100 is attached to the wall stud 37 using additional fasteners 150 through the through holes 115a, 115b; or inserting fasteners 137 into openings 136 of the shorter portion 135 of the L-shaped version of the bracket. It is to be appreciated that in other embodiments, bracket 100 may be attached in a different sequence, with flange 114 (or short portion 135) being attached to wall stud 37 before body member 104 (or long portion 131) is attached to the back of the valve box.

[0062] In some embodiments, the valve box 120 and door assembly 42 may be aligned with a cutout (not shown) on opposite ends of the wall 70 and may be coupled together using a plurality of fasteners 150 to engage with the boreholes (142, 147) of the door assembly 42 and the valve box 120 as illustrated in FIGS. 2B and 3. In some embodiments, there may be limited access to the door assembly side of the wall and the installer may skip the aligning and fastening the door assembly 42 with the valve box 120 and may perform this in the last step of the installation.

[0063] It is to be understood that variations, modifications, and permutations of embodiments of the present invention, and uses thereof, may be made without departing from the scope of the invention. It is also to be understood that the present invention is not limited by the specific embodiments, descriptions, or illustrations or combinations of either components or steps disclosed herein. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. Although reference has been made to the accompanying figures, it is to be appreciated that these figures are exemplary and are not meant to limit the scope of the invention. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents.

Examples

Embodiment Construction

[0048]Reference will now be made in detail to certain embodiments of the invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in reference to these embodiments, it will be understood that they are not intended to limit the invention. To the contrary, the invention is intended to cover alternatives, modifications, and equivalents that are included within the spirit and scope of the invention. In the following disclosure, specific details are given to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the present invention may be practiced without all of the specific details provided.

[0049]Referring to the drawings, wherein like reference characters designate like or corresponding parts throughout the several views, and referring particularly to FIGS. 1-11, it is seen that the present invention contains various views of a vacuum hose valve outlet box system that is o...

FIELD OF THE INVENTION

[0001] The present invention relates generally to an outlet box system and valve assembly module for a central vacuum system. More particularly, the present invention provides a vacuum hose valve outlet box assembly that is operable for engagement with a wall stud or frame member at multiple locations for stable mounting.BACKGROUND OF THE INVENTION

[0002] Vacuum hose valve outlet boxes are commonly used in residential and commercial settings to provide convenient access to ports for central vacuum systems. These boxes provide locations where a user may attach a vacuum hose for communication with a central vacuum unit. Conventional vacuum hose valve outlet box systems face several challenges and limitations. A significant issue is the complexity and inefficiency of the mounting process. Traditional systems typically require extensive manual effort to secure a valve box to a wall stud or frame member, involving multiple fasteners and the precise alignment of multiple brackets and face plates. Because of the small size of the valve box and the wide spacing between wall studs or frame members, typically only one side of the valve box is attached to the wall stud or frame member. This is usually accomplished by attaching a flange on one side (or the other side) of the front of the valve box to the front of a wall stud, such that the flange is flush against the front surface of the wall stud. Even when multiple fasteners are used to engage the flange with the wall stud, this can be a flimsy mount that is subject to detachment. Repair or replacement of installed outlet boxes can often require the removal of the interior wall finish to access the wall stud or frame member to which the box is mounted, which can lead to increased labor costs, and longer installation times.

[0003] Existing valve box designs often lack robust mechanisms for ensuring the stability and durability of the mounted system. Over time, the repeated attachment and detachment of a vacuum hose can cause the valve box to loosen or misalign, compromising the integrity of the installation. This can result in reduced performance of the vacuum system, disruption of vacuum or electrical connections, and potential damage to the wall structure. Another shortcoming of current systems is the limited accessibility and flexibility during installation. In many cases, installers face difficulties in aligning and securing the valve box and its components, particularly in tight or hard-to-reach spaces. This is further exacerbated by the need for precise positioning to ensure proper sealing and functionality of the valve box. Additionally, the design of conventional valve box systems often does not accommodate variations in wall stud configurations and dimensions. This lack of adaptability can necessitate custom modifications, adding to the complexity and cost of installation.

[0004] Overall, existing vacuum valve boxes suffer from the drawback of insubstantial and unsound mounting structures leading to performance problems and potential damages to wall structures, and from the drawback of an installation process that is not user-friendly and demands a high level of skill and precision, deterring potential users due to its complexity and the risk of installation errors. There is a clear need for a more sturdy, streamlined, adaptable, and efficient mounting apparatus and installation method for valve boxes of central vacuum systems.SUMMARY OF THE INVENTION

[0005] The present invention provides an improved vacuum hose valve outlet box mounting system and method that addresses the limitations and challenges of conventional systems. This innovative system simplifies the installation process, enhances the stability and durability of the mounted unit, and offers greater flexibility and adaptability to various wall stud configurations. A streamlined mounting method is provided and may significantly reduce the complexity and inefficiency associated with traditional systems.

[0006] The present invention provides an outlet box having a plurality of flanges at the corners of the box and a novel additional bracket with features that engage with a rear surface of the outlet box. The outlet box flanges and the additional bracket have through holes that are operable to receive fasteners for laterally and longitudinally attaching the outlet box to a wall studs or frame member with ease. In some embodiments, the bracket design may have a T-shaped body with flange members and through holes for receiving fasteners. In some embodiments, the interior surface of the bracket may feature snap tabs that engage with receiving apertures on the valve box, enabling a quick and secure lateral attachment to a wall stud or frame member. Embodiments of the present invention reduce the need for precise alignment and minimizes the risk of installation errors.

[0007] Embodiments of the valve box of the present invention are operable to house a suction port of a central vacuum system and securely attach it to a wall. Embodiments of the valve box include a side surface at the front of the valve box featuring a pair of flanges positioned at the corners, facilitating side attachment to a wall stud. Embodiments of the valve box may include a plurality of boreholes for securing a door assembly and compressing a sealing member, the sealing member being operable to allow for mounting and sealing to interior surface finishes of varying thickness. Embodiments of the valve box may have a symmetrical design that allows for securing to a wall studs or frame on either the right or left side of the valve box, ensuring versatile installation options.

[0008] Embodiments of the bracket may include rear bracket comprising a T-shaped member having a horizontal body with a perpendicular flange located on at least one end of the body. One or more through holes may be provided on the flange member, and may positioned symmetrically above and below the attachment to the horizontal body. An interior surface of the horizontal body may includes snap tabs designed to engage with the receiving apertures or structures on a rear surface of the valve box. In alternative embodiments, one or more through holes may be provided on the horizontal body to receive one or more fasteners (e.g., self-tapping screws) which engage the body to the back of the valve box. In some embodiments, the back of the valve box may include openings corresponding to the through holes on the horizontal body of the bracket. When the front corners of the valve box are attached to the wall stud, and the flange of the rear bracket is fastened to the wall or stud member through the through holes, and the body member is attached to the back of the valve box, both the front and the back of the valve box are attached to the wall stud, firmly securing the valve box to the wall stud, and providing a stable and robust installation.

[0009] In some implementations of the valve box and bracket, the installation process begins before the wall board is attached to the studs or frame members. In other situations, an existing wall board must be cut out according to the dimensions of the valve box opening to reveal the stud to which the valve box will be attached. Once the stud can be accessed, the pair of flanges on a side of the valve box at the front are adjacent to the wall stud. The valve box is then longitudinally secured to the wall stud by advancing fasteners through the flange through holes. It is to be appreciated that in most cases, only flanges on either the left side or the right side of the valve box (not both sides) will be used to attach to the wall stud. Following this, the rear bracket is aligned with the valve box, ensuring the fasteners or snap tabs engage securely with the receiving features or apertures on the rear of the valve box. The body of the bracket is then fastened to the rear of the valve box, and side flange is fastened to the wall stud using additional fasteners through the designated through holes.

[0010] Optionally, the door assembly can be attached by aligning it with the valve box and securing it with fasteners through the bore holes. This step compresses the sealing member between the door assembly and the valve box, ensuring horizontal securement to the wall. If access to the door assembly side is restricted, this step can be performed as the final stage of installation.

[0011] In one aspect, an embodiment of the invention provides a support structure for a central vacuum system hose outlet box comprising a housing having an interior, an exterior, a front surface, and a rear surface; at least one first flange on a first side of said front surface, and at least one second flange on an opposite second side of said front surface wherein each of said first and second flanges is operable for engagement with a wall stud; and a bracket member comprising an elongated body operable for engagement with the rear surface of said housing and a third flange member attached at one end of said elongated body wherein said third flange is operable for engagement with said wall stud. In related aspects, each of said first and second flanges may include at least one opening operable to receive a fastener for securement to a wall stud. In related aspects, a pair of first flanges are provided at a top and a bottom of said first side of said front surface and a pair of second flanges are provided at a top and a bottom of said opposite side of said front surface. In related aspects, all of the first and second flanges are mounted perpendicularly to a plane of said front surface and are operable for engagement against a side surface of a wall stud. In other aspects, all of the first and second flanges are mounted in parallel to a plane of said front surface and are operable for engagement against a front surface of a wall stud. In some aspects, the third flange includes at least one opening operable to receive a fastener for securement to a wall stud. In some aspects, the elongated body includes at least one opening operable to receive a fastener for securement to the rear surface of said housing. In some aspects, the rear surface of the housing includes at least one opening, and the elongated body includes at least one tab that is operable to snap fit into said opening to secure said elongated body against said rear surface. In some aspects, the at least one first flange is attached to a wall stud and the at least one third flange is attached to the same wall stud. In some aspects, an end of the elongated body is attached to a center of said third flange such that the bracket has a T-shape. In other aspects an end of the elongated body is attached to an end of said third flange such that the bracket has an L-shape. In some aspects, a door assembly may be provided that is secured to an exterior surface of a wall adjacent to said stud, the door assembly having a compressible sealing member that is operable to engage with a recess on a front surface of said outlet box.

[0012] 15. In other aspects, embodiments of the invention may provide a vacuum hose outlet box assembly comprising: a valve box including a front surface, a rear surface, a pair of perpendicular flanges positioned at upper and lower corners of the front surface, and at least one bore hole on each flange; a bracket member comprising an elongated body with a flange member at an end thereof, wherein the flange member has at least one through hole therein and wherein said elongated body includes at least one snap tab thereon; at least one receiving aperture on the rear surface of the valve box configured to engage with the at least one snap tab of the bracket member; and a plurality of fasteners configured to secure the valve box and the bracket to a wall stud through the at least one bore hole in each perpendicular flange and the at least one through hole in the flange member of the bracket. In related aspects, the end of the elongated body is attached to a center of said third flange such that the bracket has a T-shape. In other aspects, the end of the elongated body is attached to an end of said third flange such that the bracket has an L-shape.

[0013] In other aspects, embodiments of the invention may provide methods of installing a central vacuum outlet box comprising the steps of: positioning a pair of flanges located along a front surface of the outlet box against a surface of a wall stud; securing the outlet box to the wall stud by advancing fasteners through at least one through hole in each flange; aligning a bracket with at least one receiving aperture on a rear surface of the outlet box, the bracket comprising an elongated body with a flange member at an end thereof forming a T-shape, wherein the flange member has at least one through hole therein and wherein said elongated body includes at least one snap tab thereon; engaging the at least one snap tab of the bracket with the at least one receiving aperture on the outlet box; and fastening the bracket to the wall stud by advancing additional fasteners through the at least one through hole in the bracket flange member. In related aspects, the pair of flanges located along a front surface of the outlet box may have an orientation that is perpendicular to a plane of said front surface. In other aspects, the pair of flanges located along a front surface of the outlet box may have an orientation that is parallel to a plane of said front surface.

[0014] In different aspects, embodiments of the present invention provide a support structure for a central vacuum system hose valve housing that may include a bracket having a first member with an interior surface, an exterior surface, a proximal end, and a distal end. The bracket features a first tab and a second tab disposed on the interior surface of the first member and a flange positioned on the distal end, with at least one fastener receiver operable to receive a fastener for securement to a wall stud. The vacuum hose valve outlet box has a front and back surface, with flanges positioned at each corner of the box and a rear engagement surface with a pair of apertures complementary to the first and second tabs. The front surface of the vacuum hose valve outlet box may be aligned with the interior surface of a wall, with a pair of flanges on the same side secured to a wall stud using a fastener. The first and second tabs are engaged with the receiving apertures and fastened through at least one fastener receiver to laterally secure the hose valve housing to the wall stud. The vacuum hose outlet box flanges may protrude from the rear surface at the top and bottom corners and extend along a peripheral side edge of the rear surface. The flanges are symmetrically distributed about a vertical plane and horizontal plane of the vacuum hose valve outlet box, with centrally positioned through holes operable to receive fasteners. The valve box may include a door assembly secured to an exterior surface of the wall, the door assembly having a compressible sealing member that engages with a recess on the front surface of the vacuum hose valve outlet box. The door assembly and vacuum hose outlet box may have a plurality of complementary boreholes that align and secure the vacuum hose outlet box and door assembly on opposite sides of the wall. The receiving apertures are symmetrically distanced from the vertical plane. The first and second tabs are snapped into the receiving apertures, and the bracket flange aligns with the vacuum hose outlet box flanges. The bracket flange includes a first and second through hole positioned equidistantly from the center of the first member.

[0015] Other aspects of the present invention provide a support structure for a vacuum cleaning system hose valve housing that may include a bracket having a first member with an interior surface, an exterior surface, a proximal end, and a distal end. The bracket may feature a first tab and a second tab disposed on the interior surface of the first member and a flange positioned on the distal end, with at least one fastener receiver operable to receive a fastener for securement to a wall stud. The vacuum hose valve outlet box may have a front surface and a back surface, with flanges positioned at each corner of the box and a rear engagement surface with a pair of apertures complementary to the first and second tabs. The front surface of the vacuum hose valve outlet box may be aligned with an interior surface of a wall, with a pair of flanges on the same side secured to a wall stud using a fastener. The first and second tabs may engage with the receiving apertures and fasten through the at least one fastener receiver to laterally secure the hose valve housing to the wall stud. The vacuum hose outlet box flanges may protrude from the rear surface at the top and bottom corners and extend along a peripheral side edge of the rear surface. The flanges may be symmetrically distributed about a vertical plane and horizontal plane of the vacuum hose valve outlet box, with centrally positioned through holes operable to receive fasteners. The valve box may further include a door assembly secured to an exterior surface of the wall, the door assembly having a compressible sealing member that may engage with a recess on the front surface of the vacuum hose valve outlet box. The door assembly and vacuum hose outlet box may have a plurality of complementary boreholes that align and secure the vacuum hose outlet box and door assembly on opposite sides of the wall. The receiving apertures may be symmetrically distanced from the vertical plane. The first and second tabs may snap into the receiving apertures, and the flange of the bracket may align with the vacuum hose valve outlet box flanges. The flange of the bracket may include a first and second through hole positioned equidistantly from the center of the first member.

[0016] Additional aspects of the present invention provide a vacuum hose valve outlet box assembly, which may include a valve box with a front surface, a rear surface, a pair of perpendicular flanges at the corners of the rear surface, and a plurality of bore holes on each flange. The assembly may also include a door assembly attached to the valve box, which may feature a hinged access door and a sealing member, with the sealing member being compressible within a recess of the valve box. A bracket with a T-shaped body and a flange member at one end of the body may also be included, where the flange member may have through holes and an interior surface with snap tabs. The valve box may be equipped with a pair of receiving apertures configured to engage with the snap tabs of the bracket, and a plurality of fasteners may be provided to secure the valve box and the bracket to a wall stud through the bore holes in the flanges and the through holes in the flange member of the bracket. The valve box may align with a wall opening on the interior surface of a wall, while the door assembly aligns with the wall opening on the exterior surface of the wall, with the sealing member compressed within the recess of the valve box. The sealing member may be compressed within the recess to adjust the distance between the valve box and the door assembly, providing an airtight seal. The pair of perpendicular flanges may align with the flange member of the bracket and be fastened to the wall, securing the valve box both longitudinally and laterally.

[0017] It is another aspect of the present invention to provide a vacuum hose valve outlet box system including a vacuum hose valve outlet box, the hose outlet box having a pair of flanges positioned at the corners of the outlet box, each flange having at least one through hole. The system may include a door assembly with a hinged access door and a sealing member, the sealing member being operable to compress within a recess of the outlet box. The outlet box may have a plurality of bore holes configured to align with corresponding bore holes on the door assembly to secure the door assembly to the outlet box. The outlet box may be positioned on an interior side of a wall, while the door assembly may be positioned on an exterior side of the wall, and both may be operable to compress the wall when secured. The system may also include a bracket with a T-shaped body and a flange member on at least one end, the flange member having a pair of through holes and an interior surface with a pair of snap tabs. The valve box may be configured with a pair of receiving apertures to engage with the snap tabs of the bracket, allowing the outlet box to be secured to a wall stud through the through holes of the flanges and the through holes of the bracket, providing both longitudinal and lateral securement to the wall stud. The flanges on the outlet box may be positioned at the top and bottom corners and extend along the peripheral side edges of the rear surface, being symmetrically distributed about a vertical plane and horizontal plane of the vacuum hose valve outlet box. Each flange may have a centrally positioned through hole to receive a fastener. The receiving apertures may be symmetrically distanced from the vertical plane, and the first and second snap tabs of the bracket may engage with the receiving apertures, aligning the flange of the bracket with the flanges of the vacuum hose valve outlet box.

[0018] Finally, it is another aspect of the present invention to provide a method of assembling a vacuum hose valve outlet box assembly, that may include the steps of: preparing a wall by ensuring that a cutout aligns with the dimensions of an opening in a vacuum hose valve outlet box; inserting the vacuum hose valve outlet box into the wall cutout, positioning a pair of flanges on the valve outlet box adjacent to a wall stud; securing the vacuum hose valve outlet box to the wall stud by advancing fasteners through the through holes in the flanges; aligning a bracket with the vacuum hose valve outlet box, the bracket having a T-shaped body with a flange member, the flange member including through holes and snap tabs on an interior surface; engaging the snap tabs of the bracket with the receiving apertures on the vacuum hose valve outlet box; fastening the bracket to the wall stud by advancing additional fasteners through the through holes in the flange member; attaching a door assembly to the vacuum hose valve outlet box, the door assembly including a hinged access door and a sealing member, wherein the sealing member is compressed within a recess of the valve outlet box, ensuring a secure and airtight connection. The flange member of the bracket may align with the flanges of the vacuum hose valve outlet box to ensure both longitudinal and lateral securement. The sealing member may be compressed within the recess to adjust the distance between the valve box and the door assembly, providing an airtight seal.

[0019] Further aspects and embodiments will be apparent to those having skill in the art from the description and disclosure provided herein.

[0020] It is therefore an object of the present invention to provide methods and apparatus for securely attaching a valve box of a central vacuum system to a wall stud or frame member.

[0021] It is also an object of the present invention to provide methods and apparatus that for securely attaching both the front and the rear of a valve box of a central vacuum system to a wall stud or frame member.

[0022] It is also an object of the present invention to provide methods and apparatus for securely attaching a valve box of a central vacuum system to a wall stud or frame member that eliminates the need for precise alignment of multiple brackets and face plates, as well as the extensive manual effort typically required.

[0023] It is another object of the present invention to provide a valve box design for a central vacuum system that includes side flanges at the front of the box and a separate bracket at the rear of the box for mounting the box to a wall stud or frame member.

[0024] It is another object of the present invention to provide a mounting system for a valve box of a central vacuum system that is sturdy and less prone to damage or dislodgement under ordinary use.

[0025] The above-described objects, advantages, and features of the invention, together with the organization and manner of operation thereof, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like elements have like numerals throughout the several drawings described herein. Further benefits and other advantages of the present invention will become readily apparent from the detailed description of the preferred embodiments.BRIEF DESCRIPTION OF THE DRAWINGS

[0026] FIG. 1 provides a rear perspective environmental view of a central vacuum valve box assembly attached to a stud member, according to an embodiment of the present invention.

[0027] FIG. 2A provides an exploded perspective view of a central vacuum valve box assembly without the wall or stud, according to an embodiment of the present invention.

[0028] FIG. 2B provides a side view of a central vacuum valve box assembly, a wall and stud, and a door assembly according to an embodiment of the present invention.

[0029] FIG. 3 provides a rear environmental perspective view of a vacuum hose port valve housing positioned against a wall and stud prior to attachment of the housing to the wall and stud, according to an embodiment of the present invention.

[0030] FIG. 4 provides a rear environmental perspective view of a hose port valve housing positioned against a wall and stud during attachment of the housing to the wall and stud, according to an embodiment of the present invention.

[0031] FIG. 5 provides a rear environmental perspective view of the hose port valve housing assembly with the front thereof secured to the stud, according to an embodiment of the present invention.

[0032] FIG. 6 provides a rear environmental perspective view of a hose port valve housing with the front attached to a stud prior to attachment of a rear bracket, according to an embodiment of the present invention.

[0033] FIG. 7 provides a rear environmental perspective view of a hose port valve housing with the front attached to a stud, and a bracket attached to the back of the housing, prior to attachment of the bracket to the stud, according to an embodiment of the present invention.

[0034] FIG. 8 provides a perspective view of an embodiment of a rear bracket of the present invention.

[0035] FIG. 9 provides a side view of the embodiment of the bracket of FIG. 8.

[0036] FIG. 10 provides a top view of the embodiment of the bracket of FIG. 8.

[0037] FIG. 11 provides a rear view of a valve box, according to an embodiment of the present invention.

[0038] FIG. 12 provides a lower perspective view of a valve box, according to an embodiment of the present invention.

[0039] FIG. 13 provides a rear view of an embodiment of a valve box and rear bracket attached to a wall stud, according to an embodiment of the present invention.

[0040] FIG. 14 provides a section view of along line A-A of FIG. 13, according to an embodiment of the present invention.

[0041] FIG. 15 provides a perspective view of an alternative embodiment of a rear bracket of the present invention.

[0042] FIG. 16 provides a side view of the embodiment of the bracket of FIG. 15.

[0043] FIG. 17 provides a top view of the embodiment of the bracket of FIG. 15.

[0044] FIG. 18 provides a perspective view of another alternative embodiment of a rear bracket of the present invention.

[0045] FIG. 19 provides a side view of the embodiment of the bracket of FIG. 18.

[0046] FIG. 20 provides a top view of the embodiment of the bracket of FIG. 18.

[0047] FIG. 21 provides a front view of an alternative embodiment of a valve box of the present invention.DETAILED DESCRIPTION

[0048] Reference will now be made in detail to certain embodiments of the invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in reference to these embodiments, it will be understood that they are not intended to limit the invention. To the contrary, the invention is intended to cover alternatives, modifications, and equivalents that are included within the spirit and scope of the invention. In the following disclosure, specific details are given to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the present invention may be practiced without all of the specific details provided.

[0049] Referring to the drawings, wherein like reference characters designate like or corresponding parts throughout the several views, and referring particularly to FIGS. 1-11, it is seen that the present invention contains various views of a vacuum hose valve outlet box system that is operable to secure to a structural members in a wall using a plurality of fasteners and a rear bracket having a plurality of features that are operable to laterally secure a hose valve outlet box system to a structural members such as a wall frame or stud member.

[0050] The present invention includes a vacuum hose valve outlet box or housing 120 that is operable to house a suction port of a central vacuum system. The outlet box 120 may couple to a wall 70 and to a door assembly 42 that includes hinged access door 71 and a sealing member 41 that is operable to compress in the recess 141 of the outlet box 120.

[0051] The illustrated embodiments of the outlet box 120 may include a front surface 130 having a pair of left side flanges 146 and a pair of right side flanges 146, all of which have an orientation that is perpendicular to surface 130. It is to be appreciated that in other embodiments, a single flange may be provided on the right and left sides of the front surface 130, and in other embodiments multiple flanges may be provided on the right and left sides of the front surface 130.

[0052] In the illustrated embodiments, each of the flanges 146 are positioned at the corners of the outlet box 120, as shown in FIGS. 1-4, and may include one or more through holes 148 that is / are operable to receive one or more fasteners 150 that is / are operable to longitudinally secure the flange 146 of the valve box 120 to a wall stud 37 on either a right side or a left side of the valve box. In the illustrations of FIGS. 4 and 5, the left side of the valve box 120 (looking from the front) is attached to wall stud 37. It is to be appreciated that in other embodiments, flanges 146 may be positioned at any location along the length of either side of surface 130 of valve box 120, that multiple flanges 146 may deployed on either side, and that different numbers of flanges 146 may be provided on one side as compared to the other side of surface 130.

[0053] In other embodiments as shown in FIG. 21, one or flanges 146 may be provided on the same plane as front surface 130, or in parallel to that plane, so that these flanges may be positioned flush against a front surface of wall stud 37. In these embodiments, a single flange 146 may be provided on each side of surface 130, or multiple flanges may be provided on each side. Also, a different number of flanges 146 may be provided on one side of surface 130 as compared to the other side. Each flange 146 may include one or more through holes 148 for receiving one or more corresponding fasteners 150 to engage the flanges 146 flush against the front surface of stud 37.

[0054] The outlet box 120 may also have a plurality of bore holes 147 that align with bore holes 142 of a door assembly 42, as shown in FIG. 2A. For attachment of the door assembly, a fastener is advanced through the bore holes 142 and bore hole 147 to compress the sealing member 41 between the door assembly 42 and the outlet box 120 and horizontally securing to a wall 70 as illustrated in the steps in FIGS. 2B and 3.

[0055] In embodiments of the invention, a rear bracket 100 is provided as shown in FIGS. 6-10. Bracket 100 may have a T-shape with a longitudinal body member 104 attached perpendicularly to a flange member 114 that is provided on at least one end of body member 104. Flange member 114 may have one or more through holes 115a, 115b that may be positioned symmetrically above and below the body member 104.

[0056] Referring to the embodiment shown in FIGS. 8-10, it is seen that the illustrated body member 104 may have an interior surface 104i that has one or more snap tabs 110a, 110b that are operable to engage with corresponding receiving apertures 127a, 127b on a rear mounting surface 125 of the valve box 120. The illustrated embodiment shows a pair of snap tabs 110a, 110b and apertures 127a, 127b, as shown in FIGS. 6, 11, and 12. To attach bracket In assembly, as illustrated in FIG. 6 the snap tabs (110a, 110b) are aligned and clipped into the receiving apertures (127a, 127b). In these embodiments, the bracket snap tab 100b may correspond to the receiving aperture 127b, and the length of the flange member 114 from the snap tab 110b may be equal to the distance of the receiving aperture 127b to the pair flanges 146 of the valve box 120, as best illustrated in FIGS. 13-14.

[0057] It is to be appreciated that in alternative embodiments, body member 104 may include one or more openings through which one or more fasteners may be inserted for engagement of the body member 104 to a rear surface 125 of the valve box 120. Any suitable fasteners may be used for this purpose including without limitation self-tapping screws and the like.

[0058] As shown in FIG. 7, once the body member 104 is attached to the rear surface of the valve box 120, a fastener 150 corresponding to each through hole 115a, 115b of flange 114 may be advanced through the through holes and into the wall stud 37, thereby firmly securing the bracket 100 to both the wall stud 37 and the back of the valve box 120.

[0059] In alternative embodiments, such as those shown in FIGS. 15-20, bracket 100 may be provided in the form of a flat member having an L-shape with a longer portion 131 operable for attachment to the back of the valve box, and a shorter portion 135 positioned orthogonally to the longer portion for attachment to the wall stud 37. In these embodiments, one or more openings 132 may be provided on the longer portion 131 to receive fasteners 133 for engagement of the longer portion to the rear surface 125 of the valve box 120. Similarly, one or more openings 136 may be provided on the shorter portion 135 to receive fasteners 137 for engagement of the shorter portion to the wall stud 37.

[0060] It is to be appreciated that the valve box 120 is generally symmetrical such that valve box 120 may be secured to a wall stud 47 using the flanges 146 provided on either the left side 120L or the right side 120R of the valve box 120, using the same steps described and illustrated above. Similarly, bracket 100 flange member 114 is operable to be positioned adjacent to either the left side 120L or the right side 120R of the valve box, for attachment to the same wall stud member 37 as flanges 146.

[0061] To install an embodiment of a valve box of the present invention, access to a wall support stud 37 is first required. This may be accomplished during new construction before the wall panels 70 are installed, or afterwards by cutting out a section of the wall panel 70. Then, a valve box 120 of the present invention is positioned such that a pair of flanges 146 on either the right side or the left side of the valve box is adjacent to the wall stud 37. Valve box 120 may be secured to the wall stud 37 by advancing fasteners150 through the through holes 148 of side flanges 146, ensuring the box is longitudinally secured. Next, a bracket 100 is aligned with and attached to the back of the valve box 120. In some embodiments, this may be accomplished by engaging snap tabs 110a, 110b with the apertures 127a, 127b on rear surface 125 of the valve box. In other embodiments, this is accomplished by inserting one or more fasteners through openings in bracket body 104 to engage body 104 to the back 125 of the valve box 120; or inserting fasteners 133 into openings 132 of the longer portion 131 of the L-shaped version of the bracket. Finally, flange 114 of bracket 100 is attached to the wall stud 37 using additional fasteners 150 through the through holes 115a, 115b; or inserting fasteners 137 into openings 136 of the shorter portion 135 of the L-shaped version of the bracket. It is to be appreciated that in other embodiments, bracket 100 may be attached in a different sequence, with flange 114 (or short portion 135) being attached to wall stud 37 before body member 104 (or long portion 131) is attached to the back of the valve box.

[0062] In some embodiments, the valve box 120 and door assembly 42 may be aligned with a cutout (not shown) on opposite ends of the wall 70 and may be coupled together using a plurality of fasteners 150 to engage with the boreholes (142, 147) of the door assembly 42 and the valve box 120 as illustrated in FIGS. 2B and 3. In some embodiments, there may be limited access to the door assembly side of the wall and the installer may skip the aligning and fastening the door assembly 42 with the valve box 120 and may perform this in the last step of the installation.

[0063] It is to be understood that variations, modifications, and permutations of embodiments of the present invention, and uses thereof, may be made without departing from the scope of the invention. It is also to be understood that the present invention is not limited by the specific embodiments, descriptions, or illustrations or combinations of either components or steps disclosed herein. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. Although reference has been made to the accompanying figures, it is to be appreciated that these figures are exemplary and are not meant to limit the scope of the invention. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents.

Examples

Embodiment Construction

[0048]Reference will now be made in detail to certain embodiments of the invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in reference to these embodiments, it will be understood that they are not intended to limit the invention. To the contrary, the invention is intended to cover alternatives, modifications, and equivalents that are included within the spirit and scope of the invention. In the following disclosure, specific details are given to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the present invention may be practiced without all of the specific details provided.

[0049]Referring to the drawings, wherein like reference characters designate like or corresponding parts throughout the several views, and referring particularly to FIGS. 1-11, it is seen that the present invention contains various views of a vacuum hose valve outlet box system that is o...

Claims

1. A support structure for a central vacuum system hose outlet box comprising:a. a housing having an interior, an exterior, a front surface, and a rear surface;b. at least one first flange on a first side of said front surface, and at least one second flange on an opposite second side of said front surface wherein each of said first and second flanges is operable for engagement with a wall stud; andc. a bracket member comprising an elongated body operable for engagement with the rear surface of said housing and a third flange member attached at one end of said elongated body wherein said third flange is operable for engagement with said wall stud.

2. The housing of claim 1 wherein each of said first and second flanges includes at least one opening operable to receive a fastener for securement to a wall stud.

3. The housing of claim 2 wherein a pair of first flanges are provided at a top and a bottom of said first side of said front surface and a pair of second flanges are provided at a top and a bottom of said opposite side of said front surface.

4. The housing of claim 3 wherein all of said first and second flanges are mounted perpendicularly to a plane of said front surface and are operable for engagement against a side surface of a wall stud.

5. The housing of claim 2 wherein all of said first and second flanges are mounted in parallel to a plane of said front surface and are operable for engagement against a front surface of a wall stud.

6. The housing of claim 2 wherein said third flange includes at least one opening operable to receive a fastener for securement to a wall stud.

7. The housing of claim 6 wherein said elongated body includes at least one opening operable to receive a fastener for securement to the rear surface of said housing.

8. The housing of claim 6 wherein the rear surface of said housing includes at least one opening, and said elongated body includes at least one tab that is operable to snap fit into said opening to secure said elongated body against said rear surface.

9. The housing of claim 6 wherein said at least one first flange is attached to a wall stud and said at least one third flange is attached to the same wall stud.

10. The housing of claim 7 wherein said at least one first flange is attached to a wall stud and said at least one third flange is attached to the same wall stud.

11. The housing of claim 8 wherein said at least one first flange is attached to a wall stud and said at least one third flange is attached to the same wall stud.

12. The housing of claim 7 wherein an end of said elongated body is attached to a center of said third flange such that the bracket has a T-shape.

13. The housing of claim 7 wherein an end of said elongated body is attached to an end of said third flange such that the bracket has an L-shape.

14. The housing of claim 6 further comprising a door assembly secured to an exterior surface of a wall adjacent to said stud, the door assembly having a compressible sealing member that is operable to engage with a recess on a front surface of said outlet box.

15. A vacuum hose outlet box assembly comprising:a. a valve box including a front surface, a rear surface, a pair of perpendicular flanges positioned at upper and lower corners of the front surface, and at least one bore hole on each flange;b. a bracket member comprising an elongated body with a flange member at an end thereof, wherein the flange member has at least one through hole therein and wherein said elongated body includes at least one snap tab thereon;c. at least one receiving aperture on the rear surface of the valve box configured to engage with the at least one snap tab of the bracket member; andd. a plurality of fasteners configured to secure the valve box and the bracket to a wall stud through the at least one bore hole in each perpendicular flange and the at least one through hole in the flange member of the bracket.

16. The assembly of claim 15 wherein the end of said elongated body is attached to a center of said third flange such that the bracket has a T-shape.

17. The assembly of claim 15 wherein the end of said elongated body is attached to an end of said third flange such that the bracket has an L-shape.

18. A method of installing a central vacuum outlet box comprising the steps of:a. positioning a pair of flanges located along a front surface of the outlet box against a surface of a wall stud;b. securing the outlet box to the wall stud by advancing fasteners through at least one through hole in each flange;c. aligning a bracket with at least one receiving aperture on a rear surface of the outlet box, the bracket comprising an elongated body with a flange member at an end thereof forming a T-shape, wherein the flange member has at least one through hole therein and wherein said elongated body includes at least one snap tab thereon;d. engaging the at least one snap tab of the bracket with the at least one receiving aperture on the outlet box; ande. fastening the bracket to the wall stud by advancing additional fasteners through the at least one through hole in the bracket flange member.

19. The method of claim 18, wherein the pair of flanges located along a front surface of the outlet box have an orientation that is perpendicular to a plane of said front surface.

20. The method of claim 18, wherein the pair of flanges located along a front surface of the outlet box have an orientation that is parallel to a plane of said front surface.

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