Device and method for mounting an electrical box in drywall

#This invention relates to electrical boxes used to house electrical switches, outlets and/or other receptacles, more particularly a device and method for mounting an electrical box in pre-existing drywall.

#Currently, when an electrician needs to install an electrical box for a new switch or outlet in an existing wall, the electrician normally uses a gem box. A gem box measures 2″×3″ which does not allow an electrician to reach into the wall to retrieve conduit. To install a gem box, the electrician cuts a hole the same size as the gem box into drywall and then places the gem box into the hole. The gem box may be held in place by brackets on the top and bottom of the gem box which lay flat against the outer surface of the dry wall and have holes for screws. Alternatively, the gem box may be held in place by brackets on the sides of the gem box which clamp against the inner surface of the drywall when screws passing through the brackets are tightened. Both of these methods pose problems because they don't create a strong connection with the drywall meaning that over time the gem boxes may become loose or completely separated from the drywall.

#An additional problem posed by the use of gem boxes is that their size limits the electrical connections which may be made to the gem boxes and how they are made. For example, if an electrician needs to install a new switch in a wall for a ceiling fan, the electrician would have to run a line coming from a breaker panel through the top of the gem box and then a line going to the ceiling fan through the side of the gem box. This can be tedious and time consuming because of the size of the gem box. Additionally, if the electrician needs to install two switches next to each other, then two gem boxes need to be connected to each other to form a larger electrical box. Electricians would prefer to use 4″×4″ electrical boxes instead of gem boxes because they are more stable and provide more room inside of them for wires and connections as well as punch outs for running lines in and out of the 4″×4″ electrical boxes, but because of their size electricians have been unable to install 4″×4″ electrical boxes without removing large pieces of drywall so that the 4″×4″ electrical boxes can be secured to studs.

#In the following detailed description, reference will be made to the attached drawings in which:

#FIG. 1 is a side partial cutaway plan view of mounting bracket and electrical box of the present invention mounted in drywall;

#FIG. 2 is a side view of an electrical box, cover and holding wire of the present invention being mounted in drywall;

#For purposes of describing the preferred embodiments the terminology used in reference to the numbered components in the drawings is as follows: 1. electrical box 2. cover 3. mounting bracket 4. drywall 5. inner surface hole 6. outer surface 7. wall hole 8. conduit 9. screw hole 10 top plate 11. holding clip 12. screw 13. cutout bracket 14. holding wire 15. stop 16. knockout 17. stop strap 18. open end 19. closed end 20. open front 21. measure wall hole 22. cut wall hole 23. attach cover to electrical box 24. remove knock out holes 25. attach holding wire to cover 26. place electrical box through wall 27. lower electrical box in wall 28. measure conduit 29. run conduit to electrical box 30. attach stop strap 31. attach conduit to electrical box 32. repeat steps 28-31 as necessary 33. attach holding wire to mounting 34. center electrical box 35. bend holding clips 36. insert bottom screw 37. remove holding wire 38. insert top screw 39. shorten slack in conduit 40. reposition top stop strap 41. secure stop strap to top plate

#Referring now to the drawing figures, FIG. 1 depicts a side partial cutaway plan view of a mounting bracket 3 and electrical box 1 of the present invention mounted in drywall 4. The electrical box 1 has an open front 20 and is attached to a cover 2 by at least one screw 12. The cover 2 has a cut out 13 to allow for an electrical switch and/or electrical outlet to be mounted in the electrical box 1. The cover 2 rests against an inner surface 5 of the drywall 4 while the mounting bracket 3 rests against the outer surface 6 of the drywall 4. The mounting bracket 3 has a cut out 13 in the center to allow for an electrical switch and/or electrical outlet to be mounted in the electrical box is attached to the cover 2 using at least one screw 12. Holding clips 11 help hold the mounting bracket 3 in place in a wall hole 7. The mounting bracket 3 is also attached to the cover 2 by at least one screw 12. When the mounting bracket 3 and cover 2 are secured together, both act as a clamp sandwiching the drywall 4 and thereby securing the mounting bracket 3, cover 2 and electrical box 1 to the drywall 4. A conduit S is attached to the electrical box 1 at a knock out hole 16. If conduit 8 is being run vertically through a top plate 10 of a wall, as shown here in FIG. 1, then the conduit 8 may be secured to the top plate 10 using a stop strap 17, which is described further in relation FIG. 3.

#Now referring to FIG. 2, a side view of an electrical box 1, cover 2 and holding wire 14 of the present invention being mounted in drywall 4 is shown. The electrical box 1 has an open front 20 where a cover 2 is attached by at least one screw 12. A U-shaped holding wire 14 may be placed through a screw hole 9 located in the cover 2. The holding wire 14 has a stop 15 on one end to hold the cover 2 in place. A user may then place the electrical box 1 and cover 2 sideways through a wall hole 7 in the drywall 4 and use the holding wire 14 to lower the electrical box 1 and cover 2 behind the drywall 4 thereby allowing the user to attach conduit 8 to the electrical box 1 through knockout holes 16 located on the electrical box 1. The conduit 8 may be secured to a top plate 10 using a stop strap 17.