Electrical Box Backing Bracket for Puncture Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrical boxes in buildings are vulnerable to damage and potential electrocution from inadvertent punctures, especially since the location of the back of the box is not easily visible after wall completion.
Innovation Solution
The use of sturdy L-shaped brackets with an insertion flange and a base plate that can be easily inserted between the electrical box and the wall frame member, providing protection by covering the back of the box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical boxes are made of metal to withstand punctures, then protection against inadvertent punctures is improved, but cost and weight increase
Solution Approach 1:
The protection system is divided into two separate components: the original electrical box and a separate protective backing plate. The backing plate is attached to the back of the electrical box, providing puncture resistance without requiring the entire box to be made of heavy material. This segmentation allows the lightweight box to maintain its advantages while gaining the protective qualities of a metal plate.
Solution Approach 2:
The solution combines different materials to create a composite protective structure. The electrical box can remain in its original material (plastic or thin metal) while a separate backing plate, made of puncture-resistant material, is attached to its back. This composite approach provides the necessary protection while avoiding the weight and cost of making the entire box from heavy-duty material.
2Reliability
If the back of the electrical box is protected with a separate backing plate, then protection against punctures is improved, but device complexity increases
Solution Approach 1:
The protective backing plate is merged with the electrical box assembly through various attachment methods. The plate can be secured with screws, adhesives, or integration into the box mounting structure, creating a unified protective assembly that functions as a single unit while maintaining the benefits of separate components.
Solution Approach 2:
The backing plate serves multiple functions: it provides puncture protection, maintains the structural integrity of the box assembly, and can serve as a mounting surface for securing the box to wall studs. This multi-functionality reduces the need for additional components and simplifies the overall assembly process.
3Ease of operation
If face plate and fixture are used to locate the front of the electrical box, then ease of locating the front is improved, but protection of the back from punctures remains insufficient
Solution Approach 1:
The solution addresses the vulnerability of the back of the box by adding protection in a different spatial dimension. While the face plate provides visual indication in the front dimension, the backing plate provides protection in the rear dimension, creating a comprehensive protective envelope around the electrical box from both front and back perspectives.
Data Source
AI summary
The present invention provides methods and apparatus for protecting the contents of electrical boxes installed in new or existing buildings before sheetrock, drywall or wallboard is installed, by providing sturdy L-shaped brackets that include at least one insertion flange and a base plate. The flange portions of the bracket may be easily inserted (or removed) between the electrical box and the frame member to which the box is mounted, such that after insertion of the flange, the back of the box is covered and protected by the base plate. After the bracket has been installed, sheetrock, drywall or wallboard behind the electrical box may then be completed. The base plate of the bracket protects the back of the electrical box from inadvertent punctures that could occur since the location of the back of the box may not be easily determined after the wall is completed.