Adjustable Wall Mounting Frame for Retrofit Electrical Boxes
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Solution Overview
Problem
Existing methods for installing electrical components in existing building walls require significant skill and labor, as they need to be securely attached to a closed wall substrate without the opportunity to mount on a stud, making it difficult to add electrical or low-voltage devices at new locations.
Innovation Solution
A self-supporting frame apparatus that fits within a pre-set opening in the wall substrate, featuring adjustable flanges and mounting tabs to securely hold electrical boxes or low-voltage devices, allowing for easy installation by accommodating various wall thicknesses and configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrical boxes are attached to wall studs before drywall is applied, then boxes can be securely mounted in known positions, but this method cannot be used for retrofitting applications where new openings must be made in existing walls
Solution Approach 1:
The patent introduces a mounting bracket as an intermediary device that attaches to the wall substrate (drywall) and provides a secure mounting surface for electrical boxes. This bracket serves as a mediator between the electrical box and the wall substrate, enabling secure attachment in retrofitting applications where studs are not accessible.
Solution Approach 2:
The mounting system is divided into separate components: a mounting bracket that attaches to the wall substrate and electrical boxes that mount to the bracket. This segmentation allows the bracket to be independently positioned and secured to the drywall, providing adaptability for retrofitting while maintaining secure attachment capabilities.
2Adaptability or versatility
If new openings are made in existing walls for retrofitting applications, then electrical or low voltage devices can be added at new locations, but attachment of the box to the wall substrate becomes labor intensive
Solution Approach 1:
The mounting bracket is designed with pre-formed attachment features and mounting surfaces that are prepared in advance. The bracket can be quickly attached to the wall substrate using snap-fit or screw mounting mechanisms, eliminating the need for time-consuming custom fabrication or complex attachment procedures during installation.
Solution Approach 2:
The mounting bracket incorporates self-aligning features and intuitive attachment mechanisms that allow installers to quickly secure the bracket to the wall substrate without requiring specialized skills or tools. The design enables the bracket to self-position and self-secure, significantly reducing installation time and labor requirements.
3Adaptability or versatility
If mounting brackets are designed to fit various wall thicknesses and configurations, then the device becomes more versatile, but the device complexity increases
Solution Approach 1:
The mounting bracket incorporates adjustable components such as movable flanges, telescoping mounting arms, or repositionable attachment features that can be dynamically adjusted to accommodate different wall thicknesses and configurations. This dynamic adjustability provides versatility without requiring multiple specialized bracket designs for different wall types.
Solution Approach 2:
The mounting bracket is designed as a universal mounting solution that can be used with various wall substrates (drywall, plaster, wood panels) and thicknesses through standardized attachment mechanisms. The bracket integrates multiple functions including wall attachment, electrical box mounting, and positioning adjustment into a single device, reducing overall system complexity while maintaining broad adaptability.
Data Source
AI summary
A self-supporting apparatus can be placed in an opening in an existing wall substrate. A frame assembly is configured with a perimeter that can be adjusted to correspond to the opening of the wall substrate. Opposing frame portions are movable in opposite directions with respect to each other to be expandable for contact with the opening. Each frame portion comprises a first side having a detent on one surface and a second side with at least one groove on a surface thereof. The surfaces of the opposing frame portions face each other. The detents and grooves are dimensioned to provide engagement, respectively, between grooves and dents of facing frame portion surfaces.