Ceiling fan outlet box

Abstract

An improved electrical ceiling box including a top portion bounded by a peripheral side portion, with a pair of diametrically opposed ear lugs rigidly secured to the side portion. Each ear lug has a pair of ears integrally formed therewith extending inwardly into the interior cavity of the box. A first ear fits within a recess formed in the bottom edge of the box, while a second ear extends through a slot formed in the side portion of the box. The second ear has a mounting hole formed therein adapted for threaded engagement with a self-tapping screw, while the first ear has a receiving hole formed therethrough for supporting the distal end of the screw. In a preferred embodiment, the box has a substantially hexagonal configuration. In an alternative embodiment, the box has a circular configuration and is shallower, thereby eliminating the need for a pair of slots for receiving the first ears. Preferably, the ear lugs are formed from a heavier gauge material than the remainder of the box for improved strength and resistance to breakage from fatigue.

We claim:  
     
       1. An electrical ceiling box adapted to mount and support a ceiling fan, comprising: 
       a top portion;  
       a side portion rigidly coupled to said top portion and extending substantially normal thereto,  forming a box open at one end and defining an interior cavity, said side portion having an exterior surface;  
       a pair of first ears rigidly secured to said side portion and extending inwardly into said interior cavity , each of said first pair of ears having a mounting hole formed therethrough;  
       a pair of second ears rigidly secured to said side portion intermediate said first pair of ears and said top portion and extending inwardly into said interior cavity , each of said second pair of ears having a receiving hole formed therethrough, each of said receiving holes being axially aligned with one of said mounting holes, wherein each of said mounting holes is adapted to threadedly engage a screw for mounting and supporting a ceiling fan thereto, and each of said receiving holes is adapted to allow said screw to extend non-engagingly therethrough, ; and 
       said first and second pairs of ears being integrally formed on a pair of ear lugs, each of said pair of ear lugs having a web and one of said first pair of ears and one of said second pair of ears formed thereon, said first and second ears on each of said lugs being spaced a distance from each other and separated by a web  one of said first pair of ears and one of said second pair of ears on each of said lugs extending from said web toward said interior cavity, and on each of said pair of lugs said web spacing one of said first pair of ears from one of said second pair of ears thereby supporting said screw at two spaced locations along a length of said screw.  
     
     
       2. An electrical box as set forth in  claim 1 , wherein: 
       said top portion and said side portion are integrally formed with one another.  
     
     
       3. An electrical box as set forth in  claim 1 , wherein: 
       said side portion has a distal edge defining said open end of said box;  
       said side portion has a pair of slots formed therein for receiving said second ears; and  
       each of said lugs is secured to said exterior surface of said side portion with one of said first ears extending into said interior cavity adjacent said distal edge and one of said second ears extending through one of said slots.  
     
     
       4. An electrical box as set forth in  claim 1  wherein: 
       said web is spot welded to said exterior surface of said side portion.  
     
     
       5. An electrical box adapted to mount and support a ceiling fan comprising: 
       a top portion;  
       a side portion rigidly coupled to said top portion and extending substantially normal thereto, forming a box open at one end and defining an interior cavity, said side portion having an exterior surface; and  
       a pair of lugs, each of said pair of lugs having a first and a second ear integrally formed with, and separated by, a web portion, said web portion of each of said pair of lugs being rigidly secured to said side portion, said first and second ears extending inwardly into  toward said interior cavity, said first ears being disposed adjacent said open end of said box, each of said first ears having a mounting hole formed therethrough and each of said second ears having a receiving hole formed therethrough, said mounting holes being axially aligned with said receiving holes, wherein  
       each of said mounting holes is adapted to threadedly engage a screw for mounting and supporting a ceiling fan thereto, and each of said receiving holes is adapted to allow said screw to extend non-engagingly therethrough.  
     
     
       6. An electrical box as set forth in  claim 5 , wherein: 
       each of said web portions is secured to said side portion by welding.  
     
     
       7. An electrical box as set forth in  claim 5 , wherein: 
       said first ears are substantially flush with said open end of said box.  
     
     
       8. An electrical ceiling box adapted to mount and support a ceiling fan, comprising: 
       a top portion;  
       a side portion rigidly coupled to said top portion and extending substantially normal thereto, forming a box open at one end and defining an interior cavity, said side portion having an exterior surface; said side portion has a distal edge defining said open end of said box;  
       a pair of first ears rigidly secured to said side portion and extending inwardly into  toward said interior cavity, each of said first ears having a mounting hole formed therethrough;  
       a pair of second ears rigidly secured to said side portion intermediate said first ears and said top portion and extending inwardly into  toward said interior cavity, each of said second pair of ears having a receiving hole formed therethrough, each of said receiving holes being axially aligned with one of said mounting holes, wherein each of said mounting holes is adapted to threadedly engage a screw for mounting and supporting a ceiling fan thereto, and each of said receiving holes is adapted to allow said screw to extend non-engagely therethrough;  
       said first and second ears are integrally formed on a pair of ear lugs, each of said pair of ear lugs having one of said first pair of ears and one of said second pair of ears formed thereon, said first and second pairs of ears being spaced apart and separated by a web;  
       said side portion further including a pair of slots formed therein for receiving said second ears; and  
       each of said pair of ear lugs being secured to said exterior surface of said side portion with one of said first ears extending into  toward said interior cavity adjacent said distal edge and one of said second ears extending through one of said slots.  
     
     
       9. An electrical ceiling box adapted to mount and support a ceiling fan, comprising: 
       a top portion;  
       a side portion rigidly coupled to said top portion and extending substantially normal thereto, forming a box open at one end and defining an interior cavity, said side portion having an exterior surface;  
       a pair of first ears rigidly secured to said side portion and extending inwardly into  toward said interior cavity, each of said first ears having a mounting hole formed therethrough;  
       a pair of second ears rigidly secured to said side portion intermediate said first ears and said top portion and extending inwardly into  toward said interior cavity, each of said second ears having a receiving hole formed therethrough, each of said receiving holes being axially aligned with one of said mounting holes, wherein each of said mounting holes is adapted to threadedly engage a screw for mounting and supporting a ceiling fan thereto, and each of said receiving holes is adapted to allow said screw to extend non-engagingly therethrough;  
       said first and second ears being integrally formed on a pair of ear lugs, each of said ear lugs having one of said first ears and one of said second ears formed thereon, said first and second ears being spaced apart and separated by a web, said web being rigidly secured to said exterior surface of said side portion.  
     
     
       10. An electrical box adapted to mount and support a ceiling fan, comprising: 
       a top portion;  
       a side portion rigidly coupled to said top portion and extending substantially normal thereto, forming a box open at one end and defining an interior cavity, said side portion having an exterior surface; and  
       a pair of lugs each of said lugs comprises a first and second ear integrally formed with, and separated by, a web portion; and  
       said web portion of each of said lugs is rigidly secured to said side portion, said side portion has a pair of slots formed therein for receiving said second ears, said web portions being secured to said exterior surface of said side portion with said second ears extending inwardly through said slots, said first and second ears extending inwardly into  toward said interior cavity, said first ears being disposed adjacent said open end of said box, each of said first ears having a mounting hole formed therethrough and each of said second ears having a receiving hole formed therethrough, said mounting holes being axially aligned with said receiving holes, wherein  
       each of said mounting holes is adapted to threadedly engage a screw for mounting and supporting a ceiling fan thereto, and each of said receiving holes is adapted to allow said screw to extend non-engagingly therethrough.  
     
     
       11. An electrical box adapted to mount and support a ceiling fan, comprising: 
       a top portion;  
       a side portion rigidly coupled to said top portion and extending substantially normal thereto, forming a box open at one end and defining an interior cavity, said side portion having an exterior surface; and  
       a pair of lugs rigidly secured to said side portion, each of said lugs comprises a first and second ear integrally formed thereon, and each of said lugs having a central elongate web portion having an upper and lower end, one of said first ears being formed on said upper portion and one of said second ears being formed on said lower portion, said first and second ears being spaced apart and separated by said web for accommodating a screw at two spaced locations along its length,  
       said first and second ears extending inwardly into  toward said interior cavity, said first ears being disposed adjacent said open end of said box, each of said first ears having a mounting hole formed therethrough and each of said second ears having a receiving hole formed therethrough, said mounting holes being axially aligned with said receiving holes, wherein  
       each of said mounting holes is adapted to threadedly engage the screw for mounting and supporting a ceiling fan thereto, and each of said receiving holes is adapted to allow the screw to extend non-engagingly therethrough.  
     
     
       12. An electrical ceiling box adapted to mount and support a ceiling fan, comprising; 
       a top portion;  
       a side portion rigidly coupled to said top portion and extending substantially normal thereto, forming a box open at one end and defining an interior cavity, said side portion having an exterior surface;  
       a pair of first cars  ears rigidly secured to said side portion and extending inwardly into  toward said interior cavity;  
       a pair of second ears rigidly secured to said side portion intermediate said first ears and said top portion and extending inwardly into  toward said interior cavity, each of said first and second ears having an aperture for supporting a mounting screw, said first and second ears being integrally formed on a pair of ear lugs, each of said ear lugs having one of said first ears and one of said second ears formed thereon, said first and second ears on each of said lugs being positioned in axially spaced relation to each other and separated by a web, thereby supporting said screw at two spaced locations along a length of said screw , and said first and second ears on each of said lugs extending form said web toward said interior cavity. 
     
     
       13. An electrical box adapted to mount and support a ceiling fan comprising: 
       
         a top portion;  
       
       
         a side portion rigidly coupled to said top portion and extending substantially normal thereto, forming a box open at one end and defining an interior cavity, said side portion having an exterior surface; and  
       
       
         a pair of lugs rigidly secured to said side portion, each of said pair of lugs having a first and a second ear formed therewith and separated by a web portion having a vertical extent,  
       
       
         said first and second ears extending from said side portion inwardly toward said interior cavity,  
       
         said first ears being disposed adjacent said open end of said box and each having a mounting hole formed therethrough, and each of said second ears having a receiving hole formed therethrough, said mounting holes being axially aligned with said receiving holes and spaced therefrom a distance which is substantially equivalent to the vertical extent of said web, and each of said mounting holes being adapted to threadedly engage a screw for mounting and supporting a ceiling fan thereto, and each of said receiving holes being adapted to allow said screw to extend non - engagingly therethrough.   
     
     
       14. An electrical box as set forth in  claim 13 , wherein said web of at least one of said pair of lugs abuts said side portion.