Adjustable mounting bracket

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ADJUSTABLE MOUNTING BRACKET

CROSS-REFERENCE TO RELATED
APPLICATION

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This application is a divisional application of Ser. No. 11/359,768, filed Feb. 23, 2006.

FIELD OF THE INVENTION

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The present invention is directed to a mounting bracket for an electrical box or other electrical component. The invention is particularly directed to an adjustable mounting bracket for accommodating wall cavities of different depths between opposing walls. 15

BACKGROUND OF THE INVENTION

Electrical boxes are commonly mounted on various mounting brackets for securing the electrical box to a wall 20 stud or other support. The electrical boxes are dimensioned to support electrical receptacles, switches and other components and must be securely mounted to the wall stud. Many electrical boxes include a mounting bracket extending from one side of the electrical box so that only one side of the 25 electrical box is supported by the bracket. The opposite side of the electrical box often does not include a support so that some movement of the electrical box can occur during use.

To provide support of opposite ends of the electrical box, a number of brackets have been proposed. Typically, the 30 bracket includes a first member for attaching to a wall stud and a second member connected to the opposite side of the box so that both sides of the electrical box are supported to resist movement with respect to the wall.

One example of a prior support bracket is disclosed in U.S. 35 Pat. No. 4,399,922 to Horsley. The bracket as disclosed includes an extension arm bent at a right angle to a plate that supports the electrical box. The plate has one side edge provided with holes for securing the plate to a wall stud. The extension arm is formed on the opposite end and has a length 40 to contact a wall on the other side of the wall stud. The extension member includes a series of score lines that can be broken off for use with walls having different depths.

Another device is disclosed in U.S. Pat. No. 4,732,356 to Medlin. This device also includes a plate member for sup- 45 porting an electrical box. The plate includes a first end portion for attaching to the wall stud and a second end portion having an L-shaped arm to contact the opposite wall. A separate extension plate is attached to the L-shaped arm to adjust the length of the arm for different depths between the walls. 50

U.S. Pat. No. 4,688,693 to Medlin discloses an outlet box stabilizer bracket having an extension formed at a right angle to the bracket to contact an opposing wall. The extension is cut from the bracket and bent from the bracket to form a central opening in the bracket. 55

U.S. Pat. No. 4,964,525 to Coffey et al. discloses an electrical box mounting bracket for connecting to a wall stud. The bracket includes a pair of side mounted support legs that are bent at a right angle from the bracket to engage the opposite wall. 60

Examples of other mounting brackets that contact the opposing wall are disclosed in U.S. Pat. No. 4,645,089 to Horsley, U.S. Pat. No. 4,533,060 to Medlin, U.S. Pat. No. 4,569,458 to Horsley, U.S. Pat. No. 4,572,391 to Medlin, and U.S. Pat. No. 4,603,789 to Medlin. 65

While the devices and brackets have been generally suitable for the intended purpose of supporting an electrical box,

there is a continuing need in the industry for improved support brackets and methods of producing the brackets.

SUMMARY OF THE INVENTION

The present invention is directed to a mounting bracket for supporting an electrical box or other electrical component. In particular, the invention is directed to a mounting bracket for mounting an electrical component to a wall stud or other support.

A primary feature of the invention is to provide a mounting bracket for an electrical box or electrical component formed as a unitary one piece member. In one embodiment, the mounting bracket is formed from a sheet material such as steel that can be folded to a shape to support the electrical box or electrical component.

Another feature of the invention is to provide an electrical outlet box bracket that is attached to a wall stud and is able to support an electrical box by contacting an opposing wall.

A further feature of the invention is to provide a bracket for supporting an electrical box where the bracket has a support plate to contact an opposing wall and where the support plate can accommodate wall cavities of different depths. One end of the bracket can be attached to a wall stud or other support member while the support plate supports the opposite end to resist bending of the bracket.

Still another feature of the invention is to provide a bracket for supporting an electrical box where the bracket includes a support plate and an integrally formed extension plate. The extension plate can be folded in a generally outward direction with respect to the support plate to contact an opposing wall to support the electrical box.

A further feature of the invention is to provide a bracket for supporting an electrical box and mounting the electrical box to a wall stud. The bracket has a support plate extending at a right angle to the bracket and has a length to contact an opposing wall to support the bracket and resist movement of the bracket and the electrical box with respect to the wall stud. An extension plate is integrally formed with the support plate and can be folded outwardly to an extended position for contacting an opposing wall in a deep wall cavity so that the bracket can accommodate wall cavities of different depths. The extension plate can be cut from the support plate and folded outwardly to form a central opening with the support plate. In another embodiment, the extension plate is at least one and preferably two legs cut from the support plate which can be folded outwardly. In preferred embodiments, the extension plate has a bendable locking tab that can be folded over a portion of the support plate to lock the extension plate in the extended position.

These and other features of the invention are basically attained by providing an adjustable outlet box mounting bracket formed from a unitary piece of stiff sheet material. The bracket comprises a front mounting panel having a central opening with a dimension to accommodate an electrical outlet box. A plurality of first openings receive screw heads for coupling the front mounting plate to the electrical outlet box. A plurality of second openings receive fasteners for mounting the front mounting panel to a wall stud. A stabilizing plate extends from the front mounting panel at a right angle and has a first end connected to the front mounting panel and a second end to engage an opposing wall surface spaced from a front wall a first distance during use. An extension plate is coupled to the stabilizing plate at the second end and is bendable from a first position to a second extended position extending away from the stabilizing plate. The extension plate has a first end, a second end and an outer end for engaging an opposing wall surface spaced from the front wall a second distance.

The various aspects of the invention are further attained by providing an electrical box mounting bracket which com- 5 prises a front mounting panel having a central opening with a dimension to accommodate an electrical box. A plurality of first openings receive screw heads for attaching the electrical box to the front mounting panel. A plurality of second openings receive fasteners for mounting the front mounting panel 10 to a wall stud. A stabilizing plate has a first end coupled to and extending from the front mounting panel and having a second end to engage a first opposing wall surface spaced from a front wall a first distance during use. An extension plate is 15 coupled to the stabilizing plate about a first fold line and is bendable from a first position to an extended second position to engage a second opposing wall surface spaced from the front wall a second distance. A bendable locking tab is integrally formed with the bracket to secure the extension plate in 20 the extended position.

The features of the invention are also attained by providing an electrical box mounting bracket which comprises a front mounting panel having a central opening with a dimension to accommodate an electrical box. A plurality of first openings 25 receives screw heads for coupling the electrical box to the front mounting plate and a plurality of second openings for fasteners for mounting the front mounting panel to the wall stud. A stabilizing plate is coupled to a side of the front mounting panel and is bendable about a fold line to an 30 extended position wherein an outer end of the stabilizing plate engages an opposing wall surface spaced from a front wall a first distance during use. An extension plate is integrally formed with the stabilizing plate and has a first end portion and a second end portion coupled to the outer end of the 35 stabilizing plate by a fold line and a second end portion spaced from the first end portion. The extension plate is bendable about the fold line between a first retracted position and a second extended position where the second end portion extends away from the front mounting plate. 40

These and other aspects and features of the invention will become apparent from the following detailed description of the invention which taken in conjunction with the annexed drawings will become apparent to one skilled in the art.

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BRIEF DESCRIPTION OF THE DRAWINGS

The following is a brief description of the drawings, in which:

FIG. 1 is a perspective view of the mounting bracket in a 50 first embodiment of the invention showing the stabilizing plate and extension plate;

FIG. 2 is a top end view of the stabilizing plate of FIG. 1 with the extension plate in a first position and showing the wall structure; 55

FIG. 3 is a perspective view of the mounting bracket of FIG. 1 showing the extension plate in a second extended position;

FIG. 4 is a cross-sectional view of the mounting bracket of FIG. 1 taken along line 4-4 of FIG. 3 showing the locking tab 60 coupled to the support plate;

FIG. 5 is an end view of the mounting bracket of FIG. 1 showing the extension plate in the extended position contacting a wall;

FIG. 6 is an end view of the mounting bracket of FIG. 1 65 showing the extension plate in a shortened form to contact a wall;

FIG. 7 is a top plan view of a cut blank for forming a mounting bracket in a second embodiment of the invention;

FIG. 8 is an end view of the bracket of FIG. 7;

FIG. 9 is a perspective view of the folded bracket of FIG. 7;

FIG. 10 is an end view of the folded bracket of FIG. 7 showing the stabilizing plate contacting an opposing wall;

FIG. 11 is a perspective view of the mounting bracket of FIG. 7 showing the extension plate in the extended position;

FIG. 12 is a partial cross-sectional view of the locking tab folded over the stabilizing plate; and

FIG. 13 is an end view of the mounting bracket attached to a wall stud and showing the extension plate in the extended position.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to a mounting bracket for an electrical box or other electrical device. In particular, the invention is directed to a mounting bracket for securing an electrical box to a wall stud and supporting the electrical box in a secure manner.

Referring to the drawings, a first embodiment of the invention is shown in FIGS. 1-6. As shown in FIG. 1, the mounting bracket 10 includes a front mounting plate 12, a support plate 14 and an extension plate 16.

Mounting bracket 10 in a preferred embodiment of the invention is formed from a single piece of sheet material having sufficient strength to support an electrical box during use. Typically, mounting bracket 10 is formed from a steel sheet that is cut, stamped or pierced to form a one piece unitary unit. As shown in FIG. 1, front mounting plate 12 has a substantially flat front face 18 and a side portion 20 offset from the front face 18 by a stepped portion 22. Side portion 20 in the embodiment shown has a substantially rectangular shape with a plurality of apertures 24 for receiving fasteners for securing mounting bracket 10 to a wall stud 26 or other support shown in FIG. 1. Front mounting plate 12 has a central opening 28 having a dimension to receive an electrical box or other electrical component. Central opening 28 defines first and second side sections 30 and 32. Top section 34 and bottom section 36 extend between side sections 30 and 32 to define the opening 28. Front face 18 includes a plurality of apertures 38 for receiving screws or other fasteners for attaching an electrical box 40 to front plate 12 as shown in FIG. 2.

Support plate 14 in the embodiment of FIGS. 1-8 extends substantially perpendicular to front plate 12 in a direction away from front face 18. Support plate 14 has a first inner section 42 connected to side section 32 of front plate 12. Support plate 14 has a second end section 44 forming an outer end 46 spaced from front plate 12.

Extension plate 16 is integrally formed with support plate 14 and is cut or stamped from support plate 14 as shown in FIG. 1. A plurality of elongated apertures 48 are pierced in support plate 14 to define a fold line 50 between support plate 14 and extension plate 16. Extension plate 16 has side edges 52 and an outer edge 54 as shown in FIG. 3. A plurality of spaced apart score lines that define fold lines 56 are formed in extension plate 16 that are substantially parallel to fold line 50. Fold lines 56 are typically formed by stamping so that portions of extension plate 16 can be folded to reduce the effective length of extension plate 16. A central opening 58 is formed in extension plate 16 by cutting or stamping. In the embodiment illustrated, a locking tab 60 is cut from central opening 58 into extension plate 16 in a direction toward fold line 50 as shown in FIG. 1. Locking tab 60 includes side edges 62 and an outer edge 64. Extension plate 16 is cut to form top and bottom sections 66 and 68, respectively, in support plate