PLUMBING BOX WITH ADJUSTABLE BACKPLATE

Description

CROSS-REFERENCE TO RELATED APPLICATION

The subject application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/674,973 filed Jul. 24, 2024 entitled PLUMBING BOX WITH ADJUSTABLE BACKPLATE, which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The subject disclosure relates to plumbing and structures for mounting plumbing fixtures, and more particularly to an adjustable plate for installing plumbing fixtures thereto.

2. Background of the Related Art

Mixing valves or mixers and other plumbing fixtures are typically installed behind plaster board and coupled to fittings so that the user can easily operate the fixture such as selecting a desired temperature. It is desirable to not only have the resulting fixture be aesthetically pleasing but be efficient and reliable to install. Mixing valves are often mounted to a back wall or other feature of the framing. These features are often poorly placed to support and/or position the mixing valve, if the material can even easily receive mounting. Often, the installer will utilize adaptations such as plank or board haphazardly mounted behind the plaster board so that the mixer can be mounted to the plank. The result is an irregular, work intensive custom fit where the installer must take measurements, make calculations, and perform skilled compensation to try and set a proper depth of the mixing valve. Additionally, the materials used are often wood, which performs poorly in water or wet environments.

SUMMARY

In one embodiment, the subject technology is directed to a plumbing box for mounting a plumbing device having a front plate defining a central opening and screw holes. A frame extends from the front plate and has a rear support that defines three anchor holes aligned with the screw holes. Adjustment screws extend between each of the screw holes and the anchor holes so that each of the adjustment screws can freely rotate. A backplate mounts on the adjustment screws by threaded bores so rotation of any of the adjustment screws moves the backplate to a desired position within the frame. The adjustment screws may be held axially in place by a retention clip on each distal end, a self-locking nut or the like.

Preferably, the front plate includes recessed tabs that define the screw holes so that the recessed depth matches a thickness of a plasterboard that the plumbing box is to be mounted to. The plasterboard can be mounted using fasteners that are positioned using indicia on the front plate. The front plate also may form template slots for marking a surface to mount the plumbing box to.

In another embodiment, a plumbing box mounts a plumbing device such as a mixing valve. The box has a front plate defining a central opening and four screw holes. A frame extends from the front plate and has a rear support that defines four anchor holes aligned with the four screw holes. Four elongated adjustment screws extend between the four screw holes and four anchor holes, respectively, so that each of the four adjustment screws can freely rotate without axial movement. A backplate defines four threaded bores coupled to the four adjustment screws, respectively, so that the backplate is mounted on the four adjustment screws within the frame and rotation of the four screws moves the backplate axially to a desired position within the frame.

Preferably, the front plate includes four recessed tabs that define the four screw holes, the four recessed tabs being configured to receive fasteners. The front plate can also define four notches so that when connected by lines, an intersection of the lines indicates a centerpoint of the backplate. In another embodiment, the backplate has indicia, such as a grid pattern, for guiding mounting the plumbing device thereto. The front plate may defined inner corner template slots for assisting an installer to create a stencil of the central opening.

BRIEF DESCRIPTION OF THE DRAWINGS

It should be appreciated that the subject technology can be implemented and utilized in numerous ways, including without limitation as a process, an apparatus, a system, a device, a method for applications now known and later developed. So that those having ordinary skill in the art to which the disclosed technology appertains will more readily understand how to make and use the same, reference may be had to the follow drawings.

FIG. 1 is a front perspective view of a plumbing box with a mixing valve mounted thereto in accordance with the subject disclosure.

FIG. 2 is a front perspective view of a plumbing box in accordance with the subject disclosure with the backplate adjusted to the rear.

FIG. 3 is a rear perspective view of a plumbing box in accordance.

FIG. 4 is an exploded perspective view of a plumbing box in accordance with the subject disclosure.

FIG. 5 is a front view of a plumbing box in accordance with the subject disclosure.

FIG. 6 is a top view of a plumbing box in accordance with the subject disclosure.

FIG. 7 is a cross-sectional view of a plumbing box taken along cut line 7-7 on FIG. 5 in accordance with the subject disclosure.

FIG. 8 is cross-sectional detailed view to show formation of first arrangement to create a worm gear on a plumbing box in accordance with the subject disclosure.

FIG. 9 is a perspective view of a spring washer and retain ring in combination with a partial detailed cross-sectional view to show formation of second arrangement to create a worm gear on a plumbing box in accordance with the subject disclosure.

FIGS. 10-18 are a sequence of views installing a plumbing box in accordance with the subject disclosure.

FIG. 19 is a front view of another plumbing box in accordance with the subject disclosure.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The subject technology overcomes many of the prior art problems associated with installing mixers and like fixtures. The advantages, and other features of the technology disclosed herein, will become more readily apparent to those having ordinary skill in the art from the following detailed description of certain preferred embodiments taken in conjunction with the drawings which set forth representative embodiments of the present technology and wherein like reference numerals identify similar structural elements. Directional indications such as top, bottom, side, front, back, upward, downward, right, left and the like are used with respect to the figures and not meant in a limiting manner.

In brief overview with reference to FIG. 1, the subject technology is a plumbing box 100 that forms a niche 106 to house a mixer 150 mounted to a backplate 130 within the niche 106. The position of the backplate 130 is adjustable so that the installer can simply mount the mixer 150, then adjust a depth of the backplate 130 so that the mixer is in a desired position with respect to the plaster board or other requirements. The plumbing box 100 includes ample top, bottom and side openings 119a-d to pass the necessary hoses 208 with fittings 214 to plumb the mixer 150.

Referring now to FIGS. 2-7, there is shown the plumbing box 100 of FIG. 1 in various views in accordance with the subject technology. The plumbing box 100 includes a front plate 102 defining a central opening 104 for accessing the niche 106. The front plate 102 has a series of mounting holes 112a-h for securing the plumbing box 100 to plaster board as discussed below. There are four v-shaped notches 115a-d adjacent mounting holes 112b,d,f,h on a periphery 117. As can be seen, the four notches 115a-d form two opposing pairs 115a,c and 115b,d when connected by lines (not shown), an intersection of the lines will be a centerpoint 121 of the backplate 130 albeit with the intersection in the plane of the front plate 102 axially displaced above the backplate 130. It is envisioned that the centerpoint 121 does not need to be a hole but instead could be indicia such as a logo, advertising, a QR code links to instructions or product offerings and the like

The front plate 102 also includes inner corner template slots 136 for assisting the installer with mounting the plumbing box 100 on the plaster board. The template slots 136 can be provided in any shape or position but typically allow creating a stencil of the central opening 104. The front plate 102 also includes four corner tabs 108, each corner tab 108 forming a screw hole 110 for receiving a drive screw 122. The corner tabs 108 are recessed to allow room for the plaster board to fit into the central opening 104. As shown in FIG. 8, the screw holes 110 have a bent portion 111 to effectively provide a countersunk area for the drive screws 122. In one embodiment, the tabs 108 are stamped to create the bent portion 111. The recessed depth “d” of the tabs 108 with respect to the front plate 102 is preferably equal to the thickness of the plasterboard.

The front plate 102 also has four pairs of aligned diagonal marks 137. The marks 137, and optionally the mounting holes 112a,c,e,g or slots 136, facilitate locating the tabs 108 through plaster board that fills the central opening 104. As shown, the front plate 102 is square, but the front plate may be any shape such as rectangular, circular, triangular, pentagonal, hexagonal and the like. Similarly, the backplate 130 can be similarly shaped as the front plate or shaped differently. Typically, the front plate 102 is fabricated from metal by a combination of stamping and welding.

Still referring to FIGS. 2-7, a frame 114 extends from the front plate 102 rearward. The frame 114 has four corner struts 116 connected to a rear support 118. The frame 114 also includes a rear collar 123 to provide structural support. As can be seen, the plumbing box 100 has four side openings 119a-d with a top side opening 119a being relatively larger than side openings 119c-d. As such, the backplate 130 can be inserted into the niche 106 via the top side opening 119a. The rear support 118 defines four anchor holes 120 (best seen in FIG. 4) that align with the four screw holes 110 of the tabs 108, respectively. The rear support 118 is shown as square-shaped frame but like the front plate 102, the rear support does not need to be the same shape. For example, the rear support could be cross-shaped, octagonal, circular, triangular and the like.

The backplate 130 may be a unitary structure or comprised of two or more layers secured together to form a substantially planar substrate. Preferably, each corner 134 is relatively thicker to provide robust threaded corner bores 132. A front surface 131 of the backplate 130 includes indicia or grid lines 133 for guiding placement of the mixer 150. At some intersections of the grid lines 133, there are starter holes 135 and at other intersections prick punch marks 139 also for assisting with securing a fastener to the backplate 130 but any location of the front surface 131 can receive a fastener such as a self-taping screw. In another embodiment, the indicia is concentric circles or an actual pattern matched to one or more typical devices mounted on the backplate 130.

To assemble the plumbing box 100, the front plate 102 and frame 114 are formed and welded or otherwise secured together to create the structure shown in FIG. 4. Then, the backplate 130 is inserted into the niche 106 via the top side opening 119a.

Screws 122 extend through the screw holes 110 of the tabs 108 and seat flush with the respective tab 108 as shown in FIG. 8. The screws 122 have a proximal head 124 and a threaded shank portion 125 extending from the proximal head 124 to a distal end 126. As best seen in FIGS. 7-9, the screws 122 also thread through the corner threaded bores 132 but simply pass through the oversized anchor holes 120 so that each of the screws 122 can freely rotate.

In the embodiment shown in FIG. 8, to create the free rotation of the screws 122, a self-locking nut 128 couples to the distal end 126 of each screw 122. In another embodiment, the nut 128 is stuck to a strong press block or even includes an optional washer 129 (see FIG. 4). The distal end 126 may form an annular groove 141, threads or like feature so the lock nut 128 is permanently fixed in place during operation but may be removed by using a wrench if desired. This arrangement allows the screws 122 to rotate but axial motion is restricted by the respective proximal head 124 captured in the tab 108 and the distal end captured by the lock nut 128. 129

Since the shank 125 of the screws 122 is threaded into the threaded bores 132 of the backplate 130, turning any of the screws 122 will drive the backplate 130 forward and backward as shown by arrow “a” in FIG. 7. With four driving screws 122 that independently rotate, the threaded engagement to the backplate 130 drives the respective corner 134 of the backplate 130 forward or backward to a desired position. As a result, the installer can not only set a depth of the backplate 130, but the backplate 130 can also be leveled as needed. In FIGS. 1-3, 6 and 7, the backplate 130 is shown in the most rearward position.

In another embodiment shown in FIG. 9, a retention clip or ring 260 and spring washer 262 couple to each distal end 226 of the drive screws 224 for similarly limiting axial movement of the drive screws 224. The distal end 226 may form an annular groove 241 that receives the retention ring 260. The spring washer 262 is sized and configured to remove axial tolerances so that the installer has a good feel when driving the screws 224. Preferably, the screw holes 108 and anchor holes 120 are oversized compared to the threaded skank 125 so that the screws 122 can freely rotate.

In another embodiment, the threaded shank portion may have portions that are unthreaded or otherwise customized for the subject plumbing box. For example, a portion adjacent the proximal head and the distal end may not only be unthreaded, but the distal end may have features to more securely couple to the locking nut, retention clip or the like. For example, the retention feature on the distal end may be any suitable mechanism such as a cotter pin, E-clip, a cap nut and the like.

Referring now to FIGS. 10-18, a sequence of views illustrating installation of a plumbing box 100 in accordance with the subject disclosure is shown. Initially, the installer makes a tracing of the cut line in the plasterboard 200. Two intersecting lines 206 will mark a desired location for the mixer 150 on the plasterboard 200 as shown in FIG. 10. The intersection (not shown) of the lines 206 corresponds to the desired location. Preferably, the lines 206 are horizontal and vertical so that the plumbing box is easily mounted level to horizontal.

As shown in FIGS. 10 and 11, by reversing the plumbing box 100, the front plate 102 can be placed flush against the plasterboard 200. By aligning the notches 115a-d with the lines 206, the centerpoint 121 of the backplate 130 overlays, albeit axially spaced, the desired location. In other words, the plumbing box 100 becomes centered on the desired location (e.g., the intersection of the line 206). The alignment of the plumbing box 100 can be double-checked with a level.

By holding the plumbing box 100 so aligned, a pencil 202 can be used in the template slots 136 to mark the plaster board 200. The edge of the front frame 108 or a straight edge/ruler can then be used to connect the corner markings to draw a square. As shown in FIG. 12, a handsaw or other saw has been used to cut out the drywall square 204 to create a mounting opening 210 and a cut-out portion 220 (See FIG. 17). The mounting opening 210 should be sized to fit the rear support 118 but can be further adjusted such as with a file if needed. Similarly, the cut-out portion 220 should neatly fill the central opening 104 so that when placed therein against the tabs 108, a top surface of the cut-out portion 220 is flush with the front plate 102.

Once the mounting opening 210 has been formed, flexible hoses 208 can be routed as needed. The flexible hoses 108 can be hot supply, cold supply, mixed output and the like depending upon the configuration of the mixer 150 or other device. Typically, the hoses 208 are PEX pipe that provides one or more hot and/or cold lines as are needed for the particular application but can also be more rigid hard plastic and/or metal type.

Typically, the plumbing box 100 would be readied for installation by adjusting the backplate 130 fully to the rear, but such pre-positioning is not required. By having the backplate 130 rearward, the installer can more easily route the flexible hoses 108 through the side openings 119a-d into the niche 106 as shown in FIG. 13. Once the flexible hoses 208 are in position, the plumbing box 100 can be secured to the plaster board 200 with one or more fasteners 212 in the screw holes 112, preferably, while keeping the notches 115a-d aligned with the lines 206. Effectively, the front plate 102 acts as a mounting flange. As shown in FIG. 13, the flexible hoses 208 can be roughly set to a final length and prepared as needed such as with fittings 214.

Referring to FIGS. 14-16, a sequence of views of the steps to install the mixer 150 are shown. The mixer 150 or any component as desired may be mounted to the backplate 130. The backplate 130 may be made from PVC, PEHD, or even wood as well as other materials provided that the installer can easily mount the mixer 150. For example, the mixer 150 may have mounting holes or prick punch divots through which self-taping screws fix the mixer 150 to the backplate 130. The mixer 150 may also be pre-mounted to the backplate 130 before fixing the plumbing box 100 to the plaster wall 200. The flexible hoses 108 can be coupled to the mixer before and/or after mounting as is easiest for the installer.

As shown in FIG. 14, a wrench 218 is used to secure the fittings 214 to the mixer 150 before mounting the mixer 150 because being able to shift the mixer 150 off-center provides room to more easily secure the connections. Once the fittings 214 are crimped and secured to the mixer 150, the grid lines 133 provide guidance for centering the mixer 150 on the centerpoint 121, which as noted above corresponds to the desired location for the mixer 150.

As shown in FIGS. 15, the mixer has corner flanges 152, each of which forms several mounting holes 154a-d. Once the mixer 150 is centered, the mounting holes 154a-d can be checked to see if any match up with a pre-set pilot hole 135 or prick punch guide location 139 but such is not required. Since mounting hole 154d matches up with a punched guide location 139, the installer can easily deploy a self-taping screw there. In another embodiment, the backplate has tighter grid lines with more pilot locations to more accurately center the mixer without additional measurement.

Once screws are in place to secure the mixer 150 to the backplate 130, the depth and/or leveling of the mixer 150 within the plumbing box 100 can be adjusted and set. As shown in FIG. 16, a drill 230 or screwdriver can be used to turn each of the four drive screws 122. As a drive screw 122 turns, the threaded shank 125 interacts with the respective threaded bore 132 of the backplate 130 to move the respective corner of the backplate 130. This worm drive effect can be used to not only change the depth of the backplate 130 and, in turn, the mixer 150 mounted thereon, but level the mixer 150 as well. A ruler 240 can be used to check a depth of the backplate 130 and mixer 150 with respect to the plasterboard 200 and/or front plate 102. A level (not shown) can also be used to very the desired orientation of the mixer 150.

Referring to FIGS. 17 and 18, a sequence of views of the steps to enclose and seal the plumbing box 100 with an installed mixer 150 are shown. At any time, the cut-out portion 220 can be adapted to fit around the portion 151 of the mixer 150 extending forward of the plasterboard 200. Typically, the installer would trace and cut an outline of the portion 151 on the cut-out portion 220. The cut-out portion 220 may still have the intersection lines thereon as a guide to indicate the centerpoint. After the cut-out portion 220 is prepared, the cut-out portion 220 is inserted over the mixer 150 to substantially fill the central opening 104. It would be typical for the cut-out portion 220 to be a snug fit.

In order to screw the cut-out portion 220 to the four tabs 108, the ruler 240 is aligned with each of the four pairs of diagonal marks 137 to strike a line 223 across each corner 221 of the cut-out portion 220. These lines 223 provide a guide so that the installer can successfully drive a screw 225 through the cut-out portion 220 into the respective tab 108 at a proper location. One proper location is the center of the line 223, which may simply be eyeballed or a 45 degree diagonal line can be drawn down from the front plate corner to create an intersection at the center of each line 223. Preferably, the tabs 108 are shaped so that inexact and other locations are also suitable. For example in the pie-shaped tabs 108, there are two suitable screw anchor positions 109 adjacent the front plate 102 (see FIGS. 15 and 17). The installer can also easily find these by using the diagonal marks 137 and front plate 102 for guidance. To secure the cut-out portion 220 in place in the central opening, the installer uses several screws 225 in the proper locations, typically one in each corner.

Although the cut-out portion 220 is snugly mount in place to enclose the central opening 104 of the plumbing box 100, sealing the plumbing box 100 is preferred. Prior to mounting, the plumbing box 100 and the cut-out portion 220 can be used as a pattern to create a glass cloth layer 270. By placing the glass cloth layer 270 around the mixer 150 and over the front plate 102. To complete the sealing, liquid waterproofing membrane 272 is applied on to the glass cloth layer 270 with a paint roller 274.

As can be seen, the installer need not make advance calculation and/or makeshift compensation, but rather simply mount the components properly and turn the adjustment screws 122 to set the mixer 150 in the desired position with respect to the plaster board 200 or any other desirable considerations. Once the plumbing box 100 is water sealed, the installer may apply tiles 350 over the front frame 108, cut-out portion 220 and dried membrane 270. The escutcheon, control handle and other components as needed are connected to complete the installation.

Referring now to FIG. 19, another version of a plumbing box 300 is shown, but many features are the same so that the following description is only directed to primary differences and utilizes similar reference numbers in the 300 series. The tabs 308 are again recessed to a depth approximately equal to the plaster board but of a rectangular shape. The tabs 308 still provide ample room to receive a self-tapping screw (not shown) to fix the cut-out plasterboard thereto. The template slot 336 also have a different shape and arrangement. In one embodiment, the top and bottom template slots 336 are so positioned adjacent the tabs 308 that along with the front plate 302, guidance is provided for the installer to locate the fasteners to secure the plasterboard cut-out to the tabs 308 to enclose the central opening 304. In another embodiment, there is indicia on the front plate to indicate where to drive fasteners to secure the plasterboard cut-out to the tabs.

It will be appreciated by those of ordinary skill in the pertinent art that the functions of several elements may, in alternative embodiments, be carried out by fewer elements, or a single element. Similarly, in some embodiments, any functional element may perform fewer, or different, operations than those described with respect to the illustrated embodiment. Also, functional elements (e.g., screws, fasteners, frames, plates, tabs, retention clips, nuts and the like) shown as distinct or integral for purposes of illustration may be incorporated within other functional elements or separated into multiple components in a particular implementation. Further, although the subject technology has been desired with respect to mixers, it is envisioned that the subject technology would be equally applicable to other devices.

Reference numerals in the claims are only for illustration and not limiting with respect to other embodiments, structures and versions.

While the subject technology has been described with respect to preferred embodiments, those skilled in the art will readily appreciate that various changes and/or modifications can be made to the subject technology and claims without departing from the spirit or scope of the invention. For example, each claim may depend from any or all claims in a multiple dependent manner even though such has not been originally claimed and various components and features may be added into other claims or removed from the original claims.