Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
  • H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
  • H02G3/02—Details
  • H02G3/08—Distribution boxes; Connection or junction boxes
  • H02G3/12—Distribution boxes; Connection or junction boxes for flush mounting
  • H02G3/123—Distribution boxes; Connection or junction boxes for flush mounting in thin walls
  • H02G3/125—Distribution boxes; Connection or junction boxes for flush mounting in thin walls with supporting bar extending between two separate studs of a wall frame
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
  • H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
  • H02G3/02—Details
  • H02G3/08—Distribution boxes; Connection or junction boxes
  • H02G3/12—Distribution boxes; Connection or junction boxes for flush mounting
  • H02G3/123—Distribution boxes; Connection or junction boxes for flush mounting in thin walls
  • H02G3/126—Distribution boxes; Connection or junction boxes for flush mounting in thin walls with supporting means for mounting on a single wall stud
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
  • H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
  • H02G3/30—Installations of cables or lines on walls, floors or ceilings
  • H02G3/32—Installations of cables or lines on walls, floors or ceilings using mounting clamps

Definitions

• the support assembly may be used for various purposes, such as to hold an electrical box or to secure and guide cables within a studded wall.
• the support assembly includes a wall stud bracket for fastening the support assembly to a wall stud.
• some applications require using a support assembly which includes a two part telescoping strut for supporting an electrical box or similar device in a studded wall.
• the support assembly includes a pair of wall stud brackets connected with the telescoping strut, one on each end of the strut, which are then each fastened to a wall stud.
• the support assembly includes a structural member used to position or guide flexible conduit or cable within a wall.
• the support assembly may include a wall stud bracket which is connected with the structural member used guide and position the flexible conduit or cable at a predetermined distance from the face of a drywall member which is later fastened to a wall stud.
• these support assemblies are stamped sheets or strips of metal that are secured to a wall stud using a screw fastener.
• support assembly are also difficult to fasten to a wall stud since an installer would typically need to hold the support assembly with one hand and a fastener, such as a screw or nail, and fastening device, such as a screw driver or hammer, with another hand. The installer would then have to insert the fastener into the support assembly, or a wall stud bracket connected with the support assembly, while holding the support assembly in the correction location on the stud, otherwise the support assembly would fall to the floor. Additionally, some support assemblies have a difficult time engaging and holding certain types of conduit or cable, such as armored cable which is protected by a corrugated metal sheathing.
• a support assembly which can be more easily fastened to a stud and which does not require that the wall stud bracket be held in positioned by an installer in order to fasten the support assembly to a wall stud.
• a support assembly with a strut having the box securing advantages of the noted prior art strut, which could quickly be field formed to accommodate various box depths, while at the same time could be readily mounted to any interior or exterior surface of a metal stud, or the exterior of a wood stud.
• a support assembly which can engage and hold a certain types of conduit or cable, such as armored cable which is protected by a corrugated metal sheathing.
• At least a portion of the first compressible member extends from either the first engagement member or the second engagement member in a first direction Dj either from the first engagement member towards the second engagement member or from the second engagement member towards the first engagement member.
• the first compressible member is compressible in a second direction D 2 opposite that of the first direction D 1 .
• FIG. 1 depicts a perspective view of an electrical box support assembly for mounting an electrical box between a pair of studs, in accordance with one embodiment.
• FIG. 2 depicts a first side view of a first engaging tab for the electrical box support assembly shown in FIG. 1 for mounting an electrical box between a pair of studs, in accordance with one embodiment.
• FIG. 3 depicts a first perspective view of the first engaging tab shown in FIG. 2 for mounting an electrical box between a pair of studs, in accordance with one embodiment.
• FIG. 4 depicts a second perspective view of the first engaging tab shown in FIG. 2 for mounting an electrical box between a pair of studs, in accordance with one embodiment.
• FIG. 5 depicts a second side view of the first engaging tab shown in FIG. 2 connected with a stud in a first manner, in accordance with one embodiment.
• FIG. 6 depicts a first perspective view of the first engaging tab shown in FIG. 2 connected with a stud in a first manner, in accordance with one
• FIG. 8 depicts a side view of the first engaging tab shown in FIG. 2 connected with a stud in a second manner, in accordance with one embodiment.
• FIG. 9 depicts a first perspective view of the first engaging tab shown in FIG. 2 connected with a stud in a second manner, in accordance with one embodiment.
• FIG. 34 depicts a perspective view of a conduit/cable support assembly, in accordance with one embodiment.
• FIG. 36 depicts a perspective view of a conduit/cable support assembly in a first position, in accordance with one embodiment.
• FIG. 37 depicts a perspective view of a conduit/cable support assembly, in accordance with one embodiment.
• FIG. 38 depicts a top view of a conduit/cable, in accordance with one embodiment.
• FIG. 39 depicts a perspective view of a conduit/cable support assembly, in accordance with one embodiment.
• Additional methods and device consistent with the present invention overcome disadvantages of conventional support assemblies which use a wall stud bracket fastened to a wall stud to support a structural member by using an engaging tab for connecting the structural member with the wall stud.
• the engaging tab includes a pair of engagement members which engage non-mounting faces of the wall stud, a side engagement member which engages a mounting face of the wall stud, and a compressible member connected with one of the
• Additional methods and device consistent with the present invention overcome disadvantages of conventional support assemblies which are used to position or guide flexible conduit or cable within a wall and use a wall stud bracket fastened to a wall stud to support a structural member by using an engaging tab for connecting the structural member with the wall stud.
• an engaging tab along with a compressible member, a support assembly may be fastened to a wall stud more easily, since once engaged with the stud, the compressible member can hold the support assembly in a set position while an installer may insert additional fasteners through portions of the support assembly in order to securely fasten the support assembly to a wall stud.
• the structural member 213 includes any structure which is connected with the engaging tab 140 and is required to be coupled with wall stud 110, such as a two part telescoping strut 120, 130 for supporting an electrical box 102 or similar device in a studded wall, a securing arm 220 for securing and/or guiding flexible conduit/cable 270 within a wall, a uni-body face plate or sheet providing mounting locations for one or many electrical junction boxes (these could hang from the side of the stud or span across multiple studs), or struts used to support plurality of rigid conduit or electrical metallic tubing.
• a two part telescoping strut 120, 130 for supporting an electrical box 102 or similar device in a studded wall
• a securing arm 220 for securing and/or guiding flexible conduit/cable 270 within a wall
• a uni-body face plate or sheet providing mounting locations for one or many electrical junction boxes (these could hang from the side of the stud or span across multiple studs)
• studs In North America, studs are typically placed a distance di of approximately 16 inches (400 mm) ⁇ 1 inch ( ⁇ 25 mm) from each other's center, but sometimes also at a distance di of 12 inches (300 mm) ⁇ 1 inch ( ⁇ 25 mm), or a distance di of 24 inches (600 mm) ⁇ 1 inch ( ⁇ 25 mm).
• Studs 110 may have additional widths as well, such as 1.625 inches (41.3mm) ⁇ 0.25 inches ( ⁇ 6 mm), 2.50 inches (63.5 mm) ⁇ 0.25 inches ( ⁇ 6 mm), 3.625 inches (92 mm) ⁇ 0.25 inches ( ⁇ 6 mm), 4.0 inches (101.6 mm) ⁇ 0.25 inches ( ⁇ 6 mm), and 6 inches (152.4 mm) ⁇ 0.25 inches ( ⁇ 6 mm).
• each telescoping strut 120, 130 overlaps first telescoping strut 120, as first telescoping strut 120 slides underneath and telescopes out from second telescoping strut 130.
• the combined length Li of the struts 120, 130 can be varied to match the distance di between the pair of studs 1 10, and allowing for easier mounting of the electrical box support assembly 100 with the studs 1 10.
• Each telescoping strut 120, 130 has a face 122, 132, respectively, to which the electrical box 102 may be secured.
• each face 122, 132 includes a mounting device, such as an opening 126 or clip, through which the electrical box 102 may be secured.
• compressible member 170 is compressed in a direction D 2 and applies a force F l in a direction D ! which is opposed to direction D 2 against the stud 1 10.
• force F l is greater than, and preferably much greater than, the weight of the electrical box support assembly 100, allowing for the engaging tab 140 to connect with and engage stud 1 10 and support the weight of the electrical box support assembly 100 along with engaging tab 190.
• an additional fastening member such as a screw or nail, is used to further secure engaging tab 140 to stud 1 10.
• engagement tongue 150 includes a bent flap 151 at an open end of the engagement tongue 150 for lifting the engagement tongue 150 upwards and away from the first engaging member 142, moving either coupling member 144 or 145 away from the locking portion 125 and into the release portion 127, allowing a user to detach the first telescoping strut 120 from the first engaging tab 140 or to reposition the first telescoping strut 120 from one position P ! to a second position p 2 .
• each compressible finger 193, 194 each of which extend from side engagement member 162, and each of which form a generally right-angle bend 197, 198, respectively, in order to wrap around either the first bulge 116 or the second bulge 117, or to wrap around a corner of the stud 110 nearest the first edge 118 or the second edge 119.
• each compressible finger 193, 194 forms an indentation 195, 196 formed in and extruded from each compressible fingers 193, 194, preferably along a grasping portion 221, 222, connected with the corner portion 197, 198, respectively, which is in turn connected with an extending portion 223, 224 which is in turn connected with the side engagement member 162.
• each bulge 116, 117 has a length of less than d 3 , so that each trailing edge 174, 175 of each winged member 172, 173 may catch and rest against a bulge 116 or 117 or an edge 118 or 119, depending on how the first engaging tab 140 is mounted to the stud 110, further securing the electrical box support assembly 100 to the stud 110.
• the second compressible member 180 includes a pair of winged members 182, 183 which slant inwardly in the second direction D 2 .
• each winged member 182, 183 is V-shaped and connected with the second engagement member 162.
• each winged member 182, 183 is simply just slanted inwardly, as shown in FIG. 4.
• each winged member 182, 183 includes a trailing edge 184, 185 respectively, which is a distance d 3 from an inward surface 166 of the side engagement member 162.
• the second compressible member 180 includes a pair of winged members 282, 283 which slant inwardly in the second direction D 2 and which include slanted upper edges 284, 285 which slant down towards and behind second engagement member 160, as shown in FIG. 25.
• each bulge 116, 117 has a length of less than d 3 , so that each trailing edge 184, 185 of each winged member 182, 183 may catch and rest against a bulge 116 or 117 or an edge 118 or 119, depending on how the first engaging tab 140 is mounted to the stud 110, further securing the electrical box support assembly 100 to the stud 110.
• the first engagement member 142 includes a pair of curved flanges 146, 147, each extending along opposing edges 148, 149 of first engagement member 142 and curving away from the second engagement member 160.
• the curved flanges 146, 147 are located on opposite sides of the first and second coupling members 144, 145 and aid in aligning and coupling the first telescoping strut 120 with the first engaging tab 140, as shown in FIG. 24.
• compressible member 170 includes a release tab 168 for moving the first compressible member 170 in the second direction D 2 and away from the stud 1 10.
• the release tab 168 aids a user in decoupling and removing the engaging tab 140 from or adjusting the engaging tab 140 against the stud 1 10.
• each bulge 1 16, 1 17 has a length of less than d 3 , so that the trailing edge 206 of the L- shaped flat spring 204 may catch and rest against a bulge 1 16 or 1 17 or an edge 1 18 or 1 19, depending on how the first engaging tab 140 is mounted to the stud 1 10, further securing the electrical box support assembly 100 to the stud 1 10.
• the L-shaped flat spring 204 includes a release tab 205 for moving the first compressible member 170 in the second direction D 2 and away from the stud 110.
• the release tab 205 aids a user in decoupling and removing the engaging tab 140 from or adjusting the engaging tab 140 against the stud 110.
• the support assembly 50 is a conduit/cable support assembly 211 connected with a stud 110 for securing and guiding conduit and/or cable 270 ("conduit/cable 270") within a wall.
• the conduit/cable 270 includes any conduit, cable or wiring which may be secured and positioned within a wall and which is preferably flexible, such as: armored cable 271 having a corrugated metal sheathing 272, as shown in FIG.
• electrical wire 276 which may be housed within the armored cable 271 and which includes any electrical wires which conduct electricity, such as copper wiring, speaker wiring, solid wiring, and stranded wiring; communications cables such as CAT5 cabling, coaxial cable, optical fiber, and twisted pair copper wiring; plumbing conduit; electrical cable or communications cable conduit; plastic conduit; and metal conduit.
• the conduit/cable support assembly 211 includes a structural member 213 connected with an engaging tab 280 for fastening the support assembly 211 to a wall stud 110.
• the structural member 213 is a securing arm 220 for securing and guiding the conduit/cable 270.
• the securing arm 220 includes a first end 222 which is connected with the engaging tab 280 opposed to a second end 224.
• the first end 222 is fixedly connected with the engaging tab 280, and therefore the engaging tab 280 does not need to include first and second coupling members 144, 145.
• the first end 222 may be removably or adjustably connected with the engaging tab 280 in one of at least two positions.
• the second end 224 may be bent upwards away from a top surface 226 at an angle a ! with respect to the top surface 226, as shown in FIG. 32.
• angle a ! is from 5° to 85°, and more preferably from 30° to 70° in order to better secure the second end 224 against the securing tab 230.
• forming a second end 224 which bends upwards at an angle of ai provides a bend which is more of a rectangular shape or U-shape at the vertex of the bend portion 250, more evenly distributing pressure across the entire length of the securing arm 220.
• the securing arm 220 forms a first stiffening flange 260 along the first outer edge 228 and a second stiffening flange 261 along the second outer edge 229, as shown in FIG. 31.
• the stiffening flanges 260, 261 are portions of the securing arm 220 which are bent along a direction D 4 from the first end 222 to the second end 224 in order to prevent the securing arm 220 from being bent in a direction D 3 from the first outer edge 228 to the second outer edge 229, as shown in FIG. 31, along any portion of the securing arm 220 in which stiffening flanges 260, 261 are present.
• the stiffening flanges 260, 261 are formed along outer edges 228, 229 of the securing arm 220 in order to selectively provide rigidity to the stiffening arm at portions of the securing arm 220 in which the stiffening flanges 260, 261 are formed.
• the stiffening flanges 260, 261 are not formed at the bend portion 250 of the securing arm 220.
• the securing arm 220 forms at least one of, and preferably a plurality of, positioning ribs 240 which extend in the direction D 3 for guiding the conduit/cable 270 along a path.
• a given conduit/cable 270 is positioned in between an adjacent pair of positioning ribs 240, as shown in FIG. 41 in order to position and guide the conduit/cable 270 within a wall.
• the securing arm 220 forms at least one securing rib 242 which extends in the direction D 4 for securing the conduit/cable 270 to the securing arm 220.
• the conduit/cable 270 is placed over the securing rib 242 along the direction D 3 , and upon moving the securing arm 220 from the first position to the second position, preferably the securing rib 242 applies some pressure onto the conduit/cable 270, securing the conduit/cable 270 to the securing arm 220.
• the securing arm 220 includes a plurality of securing ribs 242, having at least one securing rib 242 on each side of the bend portion 250.
• the securing arm 220 includes a securing rib 242 on one side of the bend portion 250 and at least one, as preferably a plurality of, positioning ribs 240 on an opposing side of the bend portion 250 allowing the securing arm 220 to be able to both guide and secure the
• the securing arm 220 forms at least one, and preferably a plurality of securing and positioning ribs 244 spaced apart from each other and which extends in the direction D 4 for both securing and positioning the conduit/cable 270.
• the conduit/cable 270 is placed in between a pair of adjacent securing and positioning ribs 244 along a direction D 3 , and upon moving the securing arm 220 from the first position to the second position, preferably the securing and positioning ribs 244 applies some pressure onto the conduit/cable 270 in addition to positioning the conduit/cable 270.
• the conduit/cable 270 forms a groove 274 or spiral channel on or around the conduit/cable 270, as shown in FIG. 38.
• the groove 274 is positioned on, and preferably mated with, a securing rib 242 or a securing and positioning rib 244 in order to further secure the conduit/cable 270 with the securing arm 220.
• the conduit/cable 270 is positioned in between an adjacent pair of positioning ribs 240, as shown in FIG. 41 in order to position and guide the conduit/cable 270 within a wall.
• an extended portion 232 of the securing tab 230 closest to the securing arm 220 is positioned at a distance d 5 from a top surface 226 of the securing arm 220.
• the distance d 5 is equal to or slightly less than a thickness t t of the conduit/cable 270 being secured by the securing arm 220 in order for the securing arm 220 to accommodate the conduit/cable 270.
• the single engaging tab 280 has a structure which mirrors that of previously discussed engaging tabs 140 or 190.
• the engaging tab 280 is coupled with the securing arm 220, and preferably, coupled with the first end 22 of the securing arm 220.
• the engaging tab 280 is fixedly coupled with the securing arm 220, however, the engaging tab 280 may be removably or adjustably coupled with the securing arm 220 in one, or more than one predetermined and fixed positions.
• the engaging tab 280 includes some or all of the elements of previously discussed engaging tabs 140 or 190, and as a result, for elements which are the same or similar, previously used element numbers will be reused.
• Engaging tab 280 includes a first engagement member 142 facing a second engagement member 160 and a side engagement 162 member connecting the first and second engagement members 142, 160 together.
• the side engagement member 162 is adapted to sit flush against a mounting face 106 of the stud 1 10, as shown in FIG 29.
• a mounting face of the stud 1 10 is the surface of the stud 1 10 upon which items, such as drywall, are mounted onto and fastened to.
• the engaging tab 280 also includes a first compressible member 170 extending in a first direction Di either from the first engagement member 142 towards the second engagement member 160 or from the second engagement member 160 towards the first engagement member 142.
• the first compressible member 170 is compressible in a second direction D 2 opposite that of the first direction D 1 .
• the first compressible member 170 is connected with one of the first engagement member 142, the second engagement member 160, and the side engagement member 162.
• at least a portion of the first compressible member 170 is extending from either the first engagement member 142 or the second engagement member 160 in a first direction Dj either from the first engagement member 142 towards the second engagement member 160 or from the second engagement member 160 towards the first engagement member 142.
• the first compressible member 170 is connected with the side engagement member 162, yet a portion 282 of the first compressible member 170 is extending from the first engagement member 142 to the second engagement member 160 in a first direction D 1 .
• the first compressible member 170 By extending in a first direction D l 5 the first compressible member 170 is able to allow the engaging tab 280 to be coupled with a wall stud 1 10, preferably by having the compressible member 170 applies a force F l 5 as shown in FIG. 8, in a direction which is opposed to that of the direction in which the compressible member 170 is compressed.
• the engaging tab 280 further includes a securing tab 230 extending from the first engagement member 142 in a second direction D 2 opposite that of the first direction D 1 .
• the securing tab 230 helps to secure and hold the second end 224 of the securing arm 220 when in the second position, helping to hold and secure any conduit/cable 270 which is sandwiched in between portions of the bent securing arm 220, when in the second position.
• the securing tab 230 is formed adjacent the first compressible member 270, from the same piece of material, wherein both are connected with the first engagement member 142.
• the engaging tab 280 further includes a second compressible member 180, wherein the first
• compressible member 170 extends from the first engagement member 142 in a first direction Di towards the second engagement member 160, and wherein the second compressible member 180 extends from the second engagement member 160 in a second direction D 2 opposite that of the first direction Di and towards the first engagement member 142.
• the engaging tab 280 is able to more securely engage the wall stud 110.
• either the first or second compressible member 170, 180 includes a pair of winged members 172, 173 which slant inwardly in the first direction Di or the second direction D 2 .
• the compressible member 170 forms a dimple 284 extending in the first direction D ! or the second direction D 2 .
• the support assembly 50 is fastened with a wall stud 110 as follows.
• an installer is provided with a support assembly 50, such as electrical box support assembly 100 or conduit/cable support assembly 211, having a structural member 213, such as telescoping struts 120, 130 or securing arm 220, and an engaging tab 140, 190 or 280 for connecting the structural member 213 with the wall stud 110.
• the engaging tab 140, 190 or 280 is coupled with an end of the structural member 213.
• conduit/cable 270 is placed in between positioning ribs 240 and/or securing and positioning ribs 244 and/or placed on top of securing rubs 242, preferably along a first portion 214 of the securing arm 220 from the first end 222 to the bend portion 250.
• a second portion 216 of the securing arm 220 from the bend portion 250 to the second end 224 is grasped by an installer and bent towards the first portion 214 of the securing arm 220 from a first position to a second position whereby the second end 224 engages and is locked in place by the securing tab 230.
• the first portion 214 and second portion 216 of the securing arm 220 sandwich and secure the conduit/cable 270 in place.
• the securing arm 220 is movable from a first position where the second end 224 is not biased against the securing tab 230 to a second position wherein the securing arm 220 is bent along the bend portion 250 and the second end 224 is biased against the securing tab 230.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Connection Or Junction Boxes (AREA)

Applications Claiming Priority (2)

Publications (1)

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Country Status (1)

Cited By (2)

Citations (6)

• 2013
  • 2013-02-12 WO PCT/US2013/025682 patent/WO2013122904A1/fr not_active Ceased

Patent Citations (6)

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