Adjustable Electrical Box Bracket for Discrete Installation Depths

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Solution Overview

Problem

Maintaining an inventory of various electrical boxes with different setbacks for residential or commercial installations is cumbersome and costly due to the unavailability of the correct setback box, leading to delays in electrical installations.

Innovation Solution

An adjustable depth electrical box with a bracket featuring interlocking structures and retention features allows the electrical box to slide between discrete positions, resisting sliding forces above a threshold and preventing overtravel, eliminating the need for expensive fasteners.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple electrical boxes with different setbacks are maintained in inventory, then different installation depth requirements can be met, but inventory complexity and cost increase

Engineering Contradiction:

Improveinstallation depth adaptabilityVSAvoidinventory complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The electrical box incorporates a slidable mechanism with a bracket that allows the box to be adjusted to multiple discrete positions along the mounting surface. This dynamic adjustment capability eliminates the need for multiple static box variants, enabling a single box design to adapt to different installation depth requirements while reducing inventory complexity

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The electrical box is designed with universal adaptability through its slidable bracket mechanism, allowing one box design to serve multiple installation depth requirements. This multi-functional capability replaces the need for specialized boxes for different setbacks, simplifying inventory management while maintaining versatility

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If the correct setback box is not available, then installation can proceed, but project delays occur

Engineering Contradiction:

Improveinstallation speedVSAvoidproject delay

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The slidable bracket mechanism enables installers to adjust the electrical box to the required depth on-site, eliminating the need to search for or order specific pre-configured boxes. This immediate adjustability prevents project delays caused by unavailable correct setback boxes while maintaining installation productivity

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If a plastic electrical box with metallic bracket and longitudinally extending screw is used, then adjustable depth is achieved, but cost increases

Engineering Contradiction:

Improvedepth adjustabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent replaces expensive metallic brackets with long-lived threaded fasteners with a simpler, more cost-effective plastic bracket design incorporating discrete positioning features. The plastic bracket with molded-in positioning elements achieves the same depth adjustment functionality at lower material and manufacturing costs, making the solution economically viable

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The design transitions from a continuous adjustment mechanism (longitudinally extending screw) to a discrete positioning system with multiple fixed depth positions. This parameter change simplifies the mechanism, reduces manufacturing complexity, and lowers costs while maintaining sufficient depth adjustability for various installation requirements

Inventive Principle:

Principle #35Parameter changes

4Adaptability or versatility

If discrete positioning features are provided, then multiple installation depths are enabled, but resistance to sliding force above threshold is reduced

Engineering Contradiction:

Improvediscrete position capabilityVSAvoidsliding resistance

Core Design Contradiction:

Adaptability or versatilityVSForce

Solution Approach 1:

The patent combines discrete positioning features with retention features into an integrated bracket design. The retention features work together with the discrete positioning elements to provide both depth selection capability and sufficient resistance to sliding forces, achieving a balance between adjustability and mechanical stability

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20240364087A1Adjustable depth electrical box

Publication Date: 2024.10.31 GENESEE A & B LLC

AI summary

An adjustable depth electrical box includes a bracket that includes a first interlocking structure and a first retention feature. An electrical box is slidably supported on the bracket and includes a second interlocking structure that is configured to slide relative to the first interlocking structure between multiple discrete positions. The electrical box has a second retention feature that cooperates with the first retention feature. The first and second interlocking structures are configured to interlock with one another in one of the multiple discrete positions and resist a sliding force above a threshold thereby providing a discrete installation depth. The first and second retention features are configured to permit uninhibited sliding of the first and second interlocking structures between first and second stops but prevent overtravel of the bracket relative to the electrical box.