Adjustable Mounting Bracket for Variable Wall Cavity Depths
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Solution Overview
Problem
Existing electrical box mounting brackets often fail to provide secure support to both sides of the electrical box, leading to potential movement during use, and do not effectively accommodate varying wall cavity depths.
Innovation Solution
A unitary, adjustable mounting bracket formed from sheet material, featuring a support plate and an integrally formed extension plate that can be folded to contact an opposing wall, with a bendable locking tab to secure the extended position, allowing for adaptation to different wall cavity depths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single bracket supports only one side of the electrical box, then the bracket structure is simple, but the electrical box experiences movement during use
Solution Approach 1:
The bracket is divided into multiple functional segments: a main body portion that attaches to the electrical box, an extension arm that reaches across the wall cavity, and a support foot that contacts the opposite wall. This segmentation allows each part to perform its specific function while collectively providing stable two-sided support.
Solution Approach 2:
The bracket extends from a single-side support configuration into a multi-dimensional structure that spans the wall cavity. The extension arm projects perpendicular to the main body, creating a L-shaped configuration that enables contact with both walls, transforming the support from one-dimensional to three-dimensional spatial engagement.
2Device complexity
If the extension arm length is fixed, then the bracket structure is simple, but it cannot accommodate wall cavities of different depths
Solution Approach 1:
The extension arm incorporates a score line that allows it to be bent at different angles, transforming a static fixed-length arm into a dynamic adjustable structure. This enables the effective length and angle of the extension arm to be modified to match various wall cavity depths while maintaining structural integrity.
Solution Approach 2:
The score line feature enables changes in the geometric parameters of the extension arm by allowing controlled bending at specific locations. This parameter modification adjusts the arm's effective length and orientation, enabling adaptation to different wall cavity dimensions without requiring multiple bracket variants.
3Adaptability or versatility
If multiple separate components are used to achieve adjustable support, then adaptability to different wall depths is improved, but the device complexity increases
Solution Approach 1:
The bracket integrates the main body, extension arm, and support foot into a single unitary component formed from one piece of sheet material. This merging eliminates the need for separate adjustment components while maintaining the adaptability to different wall depths through the integrated score line bending feature.
Solution Approach 2:
The single bracket component performs multiple functions: attaching to the electrical box, spanning the wall cavity, contacting the opposite wall, and providing adjustable length through bending. This multi-functionality is achieved within a single universal component that can adapt to various installation scenarios without requiring additional specialized parts.
Data Source
AI summary
A mounting bracket for supporting an electrical box or other electrical device to a wall stud is adapted to contact an opposing wall to resist movement of the bracket. The bracket includes a front plate and a support plate extending perpendicular to the front plate and having a length to engage the opposing wall. The extension plate is integrally formed with the support plate and can be folded to an outward extended position to increase the effective length of the stabilizing plate to accommodate wall cavities of different depths. The extension plate includes fold lines so that an end portion can be bent to shorten the effective length of the extension plate.