Adjustable Ceiling Box Assembly with Sliding Mounting Brace

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Solution Overview

Problem

Existing ceiling mounted junction boxes and mounting assemblies do not efficiently accommodate different sizes and shapes of ceiling fixtures and require multiple adjustments for screws of varying sizes, leading to increased installation time and effort.

Innovation Solution

A ceiling mounted junction box assembly with an adjustable mounting brace featuring sliding bars and end flanges that allow for adjustment in length and secure attachment to different ceiling joist or tile thicknesses, eliminating the need for additional assembly or fasteners by using screws of different sizes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a fixed mounting assembly is used, then the structure is simple, but it cannot accommodate different sizes and shapes of ceiling fixtures

Engineering Contradiction:

Improveaccommodation of different fixture sizes and shapesVSAvoidmounting assembly structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The mounting assembly incorporates a slider mechanism that allows dynamic adjustment of the electrical box position along the mounting bar. The slider can be moved to different locations and secured with screws, enabling the same assembly to accommodate various fixture sizes and shapes without requiring multiple different mounting structures.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If multiple screw sizes are supported, then versatility is improved, but installation time increases due to removing and replacing screws

Engineering Contradiction:

Improvesupport for different screw sizesVSAvoidinstallation time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The mounting assembly is pre-configured with multiple screw holes at different positions along the mounting bar and on the electrical box. This preliminary arrangement of screw holes allows installers to select the appropriate screw size and position before installation begins, eliminating the need to remove and replace screws during the installation process.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If elongated screw holes are used for adjustment, then positioning flexibility is improved, but the holding strength may be reduced

Engineering Contradiction:

Improvepositioning flexibilityVSAvoidholding strength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The mounting system segments the connection points into multiple discrete screw hole locations distributed along the mounting bar and electrical box. This segmentation allows the use of standard-sized screw holes that provide strong holding strength, while the distribution of multiple hole positions across different locations provides the necessary positioning flexibility for various fixture sizes.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11349290B2Ceiling box assembly

Publication Date: 2022.05.31 ORBIT IND INC

AI summary

Improvements in an electrical ceiling box and adjustable mounting brace assembly is disclosed. The assembly is for securing an electrical fixture to a ceiling. The adjustable mounting brace includes sliding bars, a slider and end flanges. The ceiling box can be mounted onto the slider within the sliding bars. A plurality of screw holes in the slider allows installers to use screws of different sizes to affix the electrical fixture to the slider and the electrical box by sliding the ceiling box to change its position on the mounting brace.