[0001] The present disclosure relates to a light box or junction box holder. More particularly, but not exclusively, it relates to a junction box holder for holding a junction box in place while it is embedded into a concrete slab during pouring of the slab.

BACKGROUND

[0002] Junction boxes or light boxes are used in construction to provide an enclosure in poured concrete slab ceilings that at least partially houses lighting devices or the circuitry therefor on the bottom of the slab. These are set into position before pouring of the slab. It is a problem, during the pouring of settable material such as concrete in floor slabs during construction, that movement of the concrete can cause movement of such junction boxes.

Further, use of vibrating apparatuses that stimulate movement and settling of settable material during pouring can also cause movement of junction boxes.

[0003] The present invention seeks to provide a junction box holder, which will overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.

[0004] It is to be understood that, if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art, in Australia or any other country.

SUMMARY

[0005] In one aspect there is provided a junction box holder for securing a junction box in position during pouring of settable material into formwork. The junction box holder includes a base configured for being secured to formwork operationally; and a securing frame. The securing frame extends from the base and is preferably configured for extending at least partly over the top of a junction box in operation, to thereby secure the junction box in position during pouring of said settable material. Preferably the junction box holder is. configured for holding a junction box in snug engagement to thereby secure the junction box in position during pouring of said settable material

[0006] The securing frame may include a brace configured for extending at least partly over the top of a junction box in operation, and at least one supporting leg for supporting the brace above the base. The securing frame is preferably configured to complement the shape of the junction box in operation. In one embodiment, the brace is connected to the supporting legs at a zone of engineered weakness. The zone of engineered weakness may be a perforation, notch or similar frangible formation. The zone of engineered weakness allows the brace to be removed from the supporting legs.

[0007] The supporting legs can include spacing formations of configured for supporting a similar junction box holder in a nested configuration.

Preferably the spacing formations include a flange or rib extending from at least one or more of the supporting legs, and preferably from each of the supporting legs.

[0008] Advantageously, the brace of a junction box holder can be removed and a similar junction box holder nested on top, to thereby provide an extended volume for the securing of a taller junction box.

[0009] The base may include an annular flange. Preferably, the annular flange includes an aperture having a shape that is complementary to the cross sectional shape of the junction box. The aperture in the base may be one selected from cross shaped and star shaped. The securing frame may be configured to receive the junction box via the aperture in the base.

[0010] The securing frame preferably defines at least one slot. The at least one slot may extend from the base upwardly to advantageously receive at least part of a junction box.

[0011] The securing frame may define a housing.

[0012] Preferably, the base includes one or more feet configured for supporting the base above formwork in operation. The one or more feet may be configured to be secured to formwork in operation by fasteners such as screws or nails. Preferably the one or more feet each include an aperture for receiving fasteners. Preferably each aperture is at least partially surrounded by an annular flange or rib. In a preferred embodiment, the annular flange is connected to the spacing formations by a strengthening formation. Preferably the strengthening formation is a connecting flange or rib.

[0013] Advantageously, the securing frame is configured and dimensioned to hold a junction box against formwork in operation.

[0014] In another embodiment, the securing frame is configured to be nestable with similar securing frames of similar junction box holders.

Preferably the securing frame is generally tapered upwardly. In one embodiment, the securing frame is generally frusto-conically shaped. In another embodiment, the securing frame is generally shaped as one or more selected from a tetrahedron, and a pyramid.

[0015] The junction box holder may be integrally molded in a molding process. The junction box holder may be molded of plastic.

[0016] The present disclosure discloses an apparatus that allows a junction box to be held against a formwork element in a positive manner and fastened in place by fasteners to prevent movement of the junction box during pouring of settable material into a slab.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Notwithstanding any other forms which may fall within the scope of the present invention, a preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

[0018] Figure 1 shows a top left front perspective view of a 1 ^st

embodiment of a junction box holder;

[0019] Figure 2 shows a top left front perspective view of the junction box holder of figure 1 holding a junction box;

[0020] Figure 3 shows a left side elevation view of the junction box holder of figure 1 ; [0021] Figure 4 shows a cross sectional view showing section A-A of the junction box holder of figure 3;

[0022] Figure 5 shows a top view of the junction box holder of figure 1 ;

[0023] Figure 6 shows a bottom left side view of the junction box holder of figure 1 ;

[0024] Figure 7 shows an exploded top left front perspective assembly view of a junction box holder of figure 1 and a junction box;

[0025] Figure 8 shows a bottom front perspective view of a second embodiment of a junction box holder;

[0026] Figure 9 shows a front view of the junction box holder of figure 8;

[0027] Figure 10 shows a top front perspective view of the junction box holder of figure 8;

[0028] Figure 11 shows a top front left view of the junction box holder of figure 8;

[0029] Figure 12 shows a bottom view of the junction box holder of figure

8;

[0030] Figure 13 shows a top view of the junction box holder of figure 8; and

[0031] Figure 14 shows a cutaway cross sectional view of section E-E of figure 12.

DETAILED DESCRIPTION

[0032] It should be noted in the following description that like or the same reference numerals in different embodiments denote the same or similar features.

[0033] Referring to a first embodiment shown in figures 1 -7, a light box holder or junction box holder 100 is provided. The junction box holder 100 is for holding a light box or junction box 300 in position while settable material, such as concrete, is poured into formwork (not shown), typically composed of wooden panelling, to form an inter-floor slab (not shown) on a multi-story construction, thereby embedding the junction box 300 within the slab. The junction box 300 is preferably held in position against an upper surface of the formwork by the junction box holder 100, to thereby ensure access to the junction box 300 from underneath the set slab when the formwork is removed.

[0034] For exemplary purposes only, the junction box 300 shown in figures 2 and 7 includes a cylindrically shaped housing 310, with four conduit connecting arms 320 extending horizontally outwardly at 90° intervals. The conduit connecting arms 320 are for connection to electrical conduits through which power cables (not shown) or control cables (not shown) are run, for powering lighting devices (not shown) that will be housed in the junction box 300. However, the shape of the housing 310 and the number of conduit connecting arms 320 could be varied as desired.

[0035] The junction box holder 100 includes a base 110 and a securing frame 120. The base 110 is configured for being secured to formwork operationally in a manner as described in more detail below. The securing frame 120 extends from the base 110 and is configured for extending over the top of a junction box 300 in operation (as shown in figure 2), to thereby secure the junction box 300 in position against the formwork during the pouring of settable material. Preferably the securing frame is configured for holding the junction box 300 in snug engagement. To this end, the securing frame is configured to complement the shape of the junction box 300.

[0036] The securing frame 120 includes a brace 122 in the form of an annular flange 123 that extends over the top of a junction box 300 in operation, and four supporting legs 124. The annular flange includes a central aperture 125 for facilitating the ingress of settable material through the securing frame 123 in operation. The four supporting legs are configured for supporting the annular flange 123 above the base 110.

[0037] The base 110 includes an annular flange 112 and four feet 114.

The annular flange 112 defines an aperture 116 that is shaped to be complementary to the cross-sectional shape of the junction box 300, and is configured for receiving the junction box through the aperture 116

operationally. The aperture 116 shown in the figures is generally cross shaped to receive the four conduit connecting arms 320 of the junction box 300. However in alternative embodiments, it is envisaged that the aperture 116 could be a wide variety of shapes, including star shaped or a linear slot.

[0038] It is envisaged that in alternative embodiments, the aperture 116 could also be in the form of a recess extending inwardly from an outer edge of the annular flange 112, and the term“aperture” is specifically defined to include this possibility.

[0039] Is further envisaged that in alternative embodiments, the junction box 300 need not be received within the securing frame from an opposed side of the base but could be received from the side through a recess in the base.

[0040] The base 110 further includes four feet 114 extending from the annular flange 112. In alternative embodiments (not shown) will, any number of feet may be provided. The four feet 114 are for supporting the annular flange 112 off of the formwork in operation, to allow settable material to move underneath the annular flange 112 during pouring. In this way, the annular flange 112 will not be visible from underneath the concrete slab once it has set. It is envisaged that any number of feet 114 can be provided in alternative embodiments.

[0041] As shown in figures 4 and 5, the feet 114 are cylindrical, and include apertures 115 extending longitudinally through them for receiving fasteners such as nails, to thereby secure the junction box holder 100 to wooden or similar formwork. Preferably, each of the legs 124 extend in alignment wit the apertures 115.

[0042] The securing frame 120 is generally dimensioned and configured to complement the shape of the junction box 300. The securing frame 120 defines four slots 126 extending upwardly from the base 110, each slot 126 being defined between adjacent supporting legs 124. Each slot 126 is configured for receiving one of the conduit connecting arms 320 when the junction box 300 is received by the securing frame via the aperture 116 in the base 110, as shown in figure 7.

[0043] In alternative embodiments (not shown), any number of supporting legs may be provided, defining any number of slots between them, and would typically be dependent on the number of conduit connecting arms 320 that need to be received.

[0044] The supporting legs 124 and the annular flange 123 generally together form a housing that is configured and dimensioned to complement the shape of the cylindrical junction box 300. The supporting legs 124 and annular flange 123 must also allow for settable material to move freely in and around the securing frame 120, to avoid creating voids in the settable material that are too large and that can create weaknesses in the slab.

[0045] The supporting legs 124 and annular flange 123 are also preferably configured to nest with the supporting legs and annular flange of a similar junction box holder 100. The supporting legs 124 are generally frusto- conically shaped, allowing for nesting of similar securing frames. In alternative embodiments (not shown), it is envisaged that the supporting legs 124 and brace 122 could be tetrahedrally or pyramidally shaped, or generally tapered to allow for nesting.

[0046] In a preferred embodiment, it is envisaged that the junction box holder 100 will be integrally moulded from a plastic material in a moulding process such as injection moulding, rotary moulding, blow moulding, or the like. However, it is envisaged that the junction box holder 100 can be composed of any suitable material including wood, metal, glass fibre, carbon fibre or the like. The junction box holder 100 also need not be moulded, and could be fabricated and/or assembled.

[0047] In the embodiment shown in figures 1 - 7, the brace 110 is connected to the supporting legs 124 at a zone of engineered weakness in the form of a slot 128. In alternative embodiments, it is envisaged that the zone of engineered weakness can be a perforation, notch or similar frangible formation. The zone of engineered weakness allows the brace to be conveniently broken away or removed from the supporting legs in order to nest two or more junction box holders 100 as will be described in more detail below.

[0048] In the embodiment shown in figures 8 - 14, the junction box holder 100 is provided with spacing formations 130 on each supporting legs 124. The spacing formations 130 provided in the form of a flange 131 associated with each supporting leg 124. The flanges 131 extend radially outwardly from the supporting leg 124, and extend from the base 110 to about a third up the lens of the supporting legs 124.

[0049] In alternative embodiments (not shown), it is envisaged that the spacing formations 130 need not be in the form of flanges, and instead could be provided as ribs, protrusions, studs or the like.

[0050] The spacing formations 130 are configured for allowing a pair of similar junction box holders 100 to be nested on top of each other, while spacing them at a predetermined distance apart from each other. In this configuration, it is envisaged that the bottom face of the annular flange 112 will abut against the top face of the flange 131 in this configuration. It is further envisaged that each of the spacing formations could be provided with zones of engineered weaknesses (not shown) in the form of perforations, notches, slots or the like. Such zones of engineered weaknesses allow for the spacing formations 130 to be broken off at different heights, therefore allowing for adjacent nested junction box holders 100 to be supported at varying distances from each other.

[0051] The supporting legs can include spacing formations of configured for supporting a similar junction box holder in a nested configuration.

Preferably the spacing formations include a flange or rib extending from at least one or more of the supporting legs, and preferably from each of the supporting legs.

[0052] Advantageously, the brace of a junction box holder can be removed and a similar junction box holder nested on top, to thereby provide an extended volume for the securing of a taller junction box.

[0053] In the embodiment shown in figures 8 - 14, no zones of engineered weaknesses are provided between the brace 122 and the supporting legs 124. Instead, it is envisaged that the brace 122 may be cut from the supporting legs, for example using a knife. However, it is envisaged that a zone of engineered weakness such as a perforation, notch, channel, recess or the like, may be provided in this embodiment.

[0054] In use, it is envisaged that the junction box holder 100 will be nailed to preferably wooden formwork on which it is placed, by inserting nails through the apertures 115 and hammering them in.

[0055] In the embodiment shown in figures 8 - 14, the light box holder 100 is provided with bracing formations 140 bracing the base against removal of the formwork once the settable material has been poured and set. It will be appreciated that the formwork needs to be removed while the fasteners (preferably nails) that have been used to fasten the light box holder to the formwork are withdrawn from the formwork. The provision of such bracing formations 140 allow the formwork to be removed without the base being pulled from its position in the settable material.

[0056] The bracing formations include annular aperture flanges 117 disposed around each of the apertures 115 in the base 110, as well as strengthening flanges 132 that extend between the annular aperture flanges 117 and the spacing flanges 131.

[0057] It has been found by the applicant that the rigidity allowed by connecting the annular aperture flanges 117 to the spacing formations 130 by a strengthening flange 132 is useful in use once the concrete has been poured in situ around the junction box holder 100 and set, and the formwork is removed from underneath the junction box holder. The increased rigidity allows for the nails to be more readily pulled from the formwork without bending the base 110.

[0058] The appended claims are to be considered as incorporated into the above description.

[0059] Other embodiments of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the embodiments disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.

DEFINITIONS

[0060] For the purposes of this specification, the term “plastic” shall be construed to mean a general term for a wide range of synthetic or semisynthetic polymerization products, and generally including a hydrocarbon-based polymer.

[0061] The purpose of this specification, the term “aperture” shall be construed to include both a hole extending through a body, as well as a recess extending inwardly into a body from an outer surface.

[0062] Throughout the specification, including the claims, where the context permits, the term“comprising” and variants thereof such as“comprise” or“comprises” are to be interpreted as including the stated integer or integers without excluding any other integers.

[0063] It is to be understood that the terminology employed above is for the purpose of description and should not be regarded as limiting. The described embodiments are intended to be illustrative of the invention, without limiting the scope thereof. The invention is capable of being practised with various modifications and additions as will readily occur to those skilled in the art.

[0064] Words indicating direction or orientation, such as“front”,“rear”, “back”, etc, are used for convenience. The inventor(s) envisages that various embodiments can be used in a non-operative configuration, such as when presented for sale. Thus, such words are to be regarded as illustrative in nature, and not as restrictive.

[0065] It will be appreciated that reference herein to“preferred” or “preferably” is intended as exemplary only.

Markush Groups

[0066] In addition, where features or aspects of the invention are described in terms of Markush groups, those skilled in the art will recognise that the invention is also thereby described in terms of any individual member or subgroup of members of the Markush group.

Chronological sequence

[0067] For the purpose of this specification, where method steps are described in sequence, the sequence does not necessarily mean that the steps are to be carried out in chronological order in that sequence, unless there is no other logical manner of interpreting the sequence.

Embodiments:

[0068] Reference throughout this specification to“one embodiment” or“an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases“in one embodiment” or“in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.

[0069] Similarly it should be appreciated that in the above description of example embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description of Specific Embodiments are hereby expressly incorporated into this Detailed Description of Specific Embodiments, with each claim standing on its own as a separate embodiment of this invention.

[1] Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.

Different Instances of Objects

[2] As used herein, unless otherwise specified the use of the ordinal adjectives“first”,“second”,“third”, etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner.

Specific Details

[3] In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.

Terminology

[4] In describing the preferred embodiment of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as "forward", "rearward", "radially", "peripherally", "upwardly", "downwardly", and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

[5] For the purposes of this specification, the term “plastic” shall be construed to mean a general term for a wide range of synthetic or semisynthetic polymerization products, and generally consisting of a hydrocarbon-based polymer.

[6] As used herein the term“and/or” means“and” or“or”, or both.

[7] As used herein “(s)” following a noun means the plural and/or singular forms of the noun. Comprising and Including

[8] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word“comprise” or variations such as “comprises” or“comprising” are used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

[9] Any one of the terms: including or which includes or that includes as used herein is also an open term that also means including at least the elements/features that follow the term, but not excluding others. Thus, including is synonymous with and means comprising.

Scope of Invention

[10] Thus, while there has been described what are believed to be the preferred embodiments of the invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such changes and modifications as fall within the scope of the invention. For example, any formulas given above are merely representative of procedures that may be used. Functionality may be added or deleted from the block diagrams and operations may be interchanged among functional blocks. Steps may be added or deleted to methods described within the scope of the present invention.

[11] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

Industrial Applicability

[12] It is apparent from the above, that the arrangements described are applicable to the construction industries.