Electricity: conductors and insulators – Boxes and housings
Reexamination Certificate
1999-06-09
2001-10-16
Reichard, Dean A. (Department: 2831)
Electricity: conductors and insulators
Boxes and housings
Reexamination Certificate
active
06303859
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to electrical boxes and methods of producing the same.
BACKGROUND OF THE INVENTION
Consumers, updated National Electrical Codes (NEC), and Underwriter Laboratories (UL) requirements all require that electrical boxes be made stronger than in the prior art.
OBJECTS AND SUMMARY OF THE INVENTION
An object of the invention is to overcome the drawbacks of known electrical boxes.
A further object of the invention is to provide a junction box having fixture supports for supporting at least one of light fixtures, ceiling fans, and chandeliers, for example. Another object of the invention is to provide an electrical box having at least a pair of spaced apart fixture supports, and which spaced apart fixture supports are accurately and precisely spaced apart from each other to ensure they properly mate with the mating fasteners of light fixtures, ceiling fans, and chandeliers, for example.
Another object of the invention is to provide a junction box having precise and accurate spacing between paired fixture supports that are stronger and more accurately located than prior art fixture supports, even when subjected to static and dynamic loads applied directly to the fixture supports.
Yet another object of the invention is to provide a junction box having accurately located fixture supports which are placed within the junction box “at the factory” and which stay accurately placed and strong all the way through the wholesale, retail, and transportation process until final installation by the installer.
A further object of the invention is to accurately lock added fixture supports to the junction box by locking or wedging the fixture supports and at least one of the side wall and the top wall of the junction box together.
A further object of the invention is to establish a sufficiently strong mechanical interference fit between an added fixture support and a wall of junction box so that the added fixture support is accurately and securely attached to the junction box.
Yet another object of the invention is to exploit the properties of a further reinforcement element, such as locking element or wedge, to further strengthen a connection between the added fixture support and the junction box.
Yet another object of the invention is to provide for accurate and secure placement of an added fixture support relative to top wall, as well as to the side wall of a junction box.
Another object of the invention is to provide a junction box having a fixture support therein which is accurately and securely attached to the junction box.
Another object of the invention is to provide two (2) electrical boxes in one; e.g., an installer can use the inventive electrical box to install a first type of fixture requiring a first type of fastener, and the installer can use the box to install a second type of fixture requiring a second type of fastener, so that the installer always has the proper fastener. This object also fulfills the object of reducing the amount of inventory a retailer must carry.
A further object of the invention includes making electrical boxes which use the standard punched-out, stamped electrical boxes in a more intelligent fashion.
Yet another object of the invention is to provide a standard industry size electrical box with a fixture support for supporting a fixture, and that is located the proper distance from a second fixture support, and meets National Electrical Code (NEC) standards.
Another object of the invention is to fully exploit the strength of fixture support studs, the top wall, and the side walls of electrical boxes.
A further object of the invention is to provide a junction box having fixture supports at two or four placements thereon.
A further object of the invention is to provide a junction box having four fixture supports, two fixture supports being a first type, and two fixture supports being of a second type.
A still further object of the invention is to provide a junction box suited for direct attachment to a mounting location, such as a ceiling joist, and for carrying the static and dynamic loading of a ceiling fan by itself.
Another object of the invention is to provide a junction box having a fixture support which is a rivet and/or a modified pull rivet.
Another object of the invention is to provide a junction box having a fixture support with strengthening members disposed thereon for securing the attachment of the fixture support to the junction box, as well as for enhancing the load-carrying capability of the box, such as for carrying electrical fixtures.
It is likewise an object of the invention to provide metal inserts in and/or on the electrical boxes to enhance the carrying strength of the electrical boxes.
A further object of the invention is to provide studs in the electrical boxes that enhance the carrying strength of the electrical boxes.
Yet another object of the invention is to provide studs in the electrical boxes which cover the threads of standard screws so that no screw threads are exposed in the interior of such electrical boxes.
A still further object of the invention is to provide an electrical box having a fixture support with a sufficiently smooth exterior for preventing wear to the plastic coating of plastic-coated electrical wire.
It is yet another object of the invention to provide electrical boxes in which supports, such as studs, are added during the manufacturing process to eliminate problems in prior art electrical boxes, as well as to strengthen the inventive electrical boxes.
Another object of the invention is to provide a junction box having a fixture support, yet which requires no screwing of fasteners nor welding during assembly thereof.
Yet another object of the invention is to provide an electrical box having components which are easily fabricated, added to the electrical box, and assembled in the final form by the operation of pressing or riveting, yet which do not loosen when subjected to static and/or dynamic loading.
A still further object of the invention is to provide a junction box in which the fixture support for carrying static and dynamic loads automatically extends in the desired direction along the side walls of the junction box during assembly and/or in use thanks to the fixture support being configured for engaging the side wall and/or fixture support when the support is attached and located in its attached, final form ready for use.
A still further object of the invention is to provide a junction box capable of carrying static and/or dynamic loads that has a support and that is assembled with fewer parts and with fewer steps than known devices.
It is a yet further object that all the above be carried out with an electrical box which carries the load of supported static and dynamic fixtures better than known electrical boxes.
In summary, the present invention is directed to a mounting assembly which includes an electrical junction box a top wall and a side wall. The side wall extends downwardly away from the top wall and defines a cavity therein. A fixture support extends into the cavity. Preferably, the fixture support has exposed portions which are sufficiently smooth for preventing wear to plastic-coated electrical wire which engages such exposed surfaces of the fixture support. Two or more fixture supports may be provided. An adhesive element, such as double-sided tape, may be provided on the box for rapid attachment thereof to a support surface.
The present invention is likewise directed to a mounting assembly which includes a junction box having a top wall and a downwardly extending side wall defining a cavity therein. A fixture support is provide which supports an electrical fixture, for example. The fixture support is secured to the top wall of the box by riveting the fixture fastener to the top wall of the box.
The present invention is further directed to a mounting assembly including a junction box having a top wall and a downwardly extending side wall defining a cavity therein. A fixture support extends through a hole and top wall of the junction box and is
Reichard Dean A.
Reiker Enterprises of Northwest Florida Inc.
Shlesinger & Arkwright & Garvey LLP
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