Adjustable Mounting Brace Assembly for Electrical Boxes
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Solution Overview
Problem
Existing mounting brace assemblies for electrical boxes in ceilings are often cumbersome to install and do not provide adequate support for ceiling fans and luminaires, as the weight of these devices is typically applied to the ceiling panels rather than the brace, which can lead to inadequate support and installation challenges.
Innovation Solution
A brace assembly with a hanger member that is removably coupled to a brace, allowing for adjustable positioning, and capable of being mounted to a T-bar shaped ceiling support, featuring a longitudinal slot and inwardly turned edges forming a channel for screw holes, ensuring the weight of the electrical device is supported by the brace rather than the ceiling panels, with load ratings visible post-installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If existing mounting brace assemblies are used to support electrical boxes in ceilings, then the electrical box can be mounted, but the weight of ceiling fans and luminaires is applied to the ceiling panels rather than the brace, resulting in inadequate support
Solution Approach 1:
The mounting system is divided into separate functional components: a brace assembly for structural support and an electrical box for electrical functions. The brace assembly includes a mounting bracket with mounting members that attach to ceiling supports (joists or T-bar supports), while the electrical box is separately attached to the brace. This segmentation allows the weight to be properly transferred to the structural supports through the mounting members, rather than being borne by the ceiling panels alone.
Solution Approach 2:
The mounting bracket acts as an intermediary component between the ceiling supports and the electrical box. It includes mounting members (such as screws or fasteners) that extend through openings in the bottom wall of the electrical box, creating a load path that transfers the weight of ceiling fans and luminaires through the mounting bracket to the structural ceiling supports, rather than directly to the ceiling panels.
2Strength
If existing mounting brace assemblies are installed between supports such as trusses and joists, then support is provided, but the installation process is awkward and cumbersome
Solution Approach 1:
The mounting bracket is pre-assembled with the electrical box, and the mounting members are pre-positioned with downwardly extending screws ready for installation. The brace assembly is designed to be installed between supports first, with the mounting bracket already in place to receive the electrical box. This preliminary preparation simplifies the installation process by eliminating the need for complex field assembly and positioning operations.
Solution Approach 2:
The mounting system incorporates adjustable elements that allow for dynamic adaptation during installation. The mounting bracket can be positioned at different locations along the brace, and the mounting members can be adjusted to accommodate variations in ceiling support spacing and electrical box positioning requirements, making the installation process more flexible and easier to perform.
3Ease of manufacture
If existing mounting assemblies are used, then electrical boxes can be attached, but they do not provide adequate support for the weight of ceiling fans and luminaires
Solution Approach 1:
The mounting system separates the support function (handled by the brace assembly and mounting bracket with mounting members) from the electrical function (handled by the electrical box). The mounting members with downwardly extending screws are specifically designed to bear the weight of ceiling fans and luminaires, while the electrical box is attached to the brace assembly. This segmentation ensures that the load-bearing components are optimized for strength while maintaining simple assembly procedures.
Solution Approach 2:
The load-bearing function is extracted from the electrical box itself and assigned to the separate mounting bracket and mounting members. The mounting members extend through openings in the bottom wall of the electrical box, creating a dedicated load path that isolates the weight-bearing responsibilities from the electrical box structure, allowing the electrical box to remain simple while the mounting system provides the necessary strength.
Data Source
AI summary
A brace assembly is provided having a brace for mounting to a support and a hanger member. The hanger member is coupled to the brace by a bar positioned in a longitudinal slot in the bottom side of the brace. The bar enables the hanger member to slide along the length of the brace. The hanger member has a bottom wall and side walls with a top end for coupling to a support. A mounting bracket is removably coupled to the hanger member for supporting the brace.