Adjustable-Depth Electrical Box Bracket for Flush Wall Alignment
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Solution Overview
Problem
Existing systems struggle to securely mount electrical boxes at different depths relative to support structures, such as ceilings or walls, to ensure flush alignment with internal surfaces.
Innovation Solution
A bracket system with a support body and adjustable fasteners that allow for manual adjustment of the electrical box's mounting depth by rotating threaded fasteners, either internally or externally, to align with various support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed mounting bracket is used to secure electrical boxes, then the mounting position is stable and secure, but the electrical box cannot be adjusted to different depths relative to the support structure
Solution Approach 1:
The bracket incorporates a dynamic adjustment mechanism where a fastener can be rotated along a support arm to change the mounting depth of the electrical box. The support arm allows the fastener to move longitudinally, enabling the electrical box to be positioned at various depths while remaining securely mounted. This transforms a static mounting system into a dynamic one that adapts to different depth requirements.
Solution Approach 2:
The bracket is divided into distinct functional segments: a support body that attaches to the support structure, a support arm that provides adjustment range, and a fastener that secures the electrical box. This segmentation allows each component to perform its specific function independently, enabling depth adjustment without compromising the overall structural integrity or security of the mounting system.
2Ease of operation
If the fastener is adjusted after the electrical box is mounted, then post-installation depth adjustment is enabled, but the mounting security may be compromised
Solution Approach 1:
The fastener is designed to remain dynamically adjustable even after the electrical box is initially mounted. The support arm allows the fastener to be rotated and repositioned along its length without requiring disassembly of the entire mounting system. This dynamic capability enables post-installation depth adjustments while maintaining secure mounting through the threaded engagement of the fastener with the electrical box.
3Adaptability or versatility
If a threaded fastener is used to secure the electrical box, then secure mounting is achieved, but adjustment of the electrical box depth requires rotational movement which may interfere with internal components
Solution Approach 1:
The support arm acts as an intermediary between the fastener and the electrical box. It provides a longitudinal path along which the fastener can be rotated and repositioned without the rotation directly impacting the electrical box or its internal components. This intermediary structure allows the rotational adjustment mechanism to function while minimizing interference with the mounted electrical box.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables easy and reliable adjustment of electrical box depth post-installation, maintaining flush alignment with surrounding surfaces and minimizing interference with internal components.
Implementation Method 1
The support portion can extend at an angle from an end of the extension portion opposite the support body and can be configured to retain a threaded fastener to the exterior of a back side of the electrical box so that rotational adjustment of the fastener relative to the support portion moves the electrical box to be secured at any of a plurality of depths relative to the support body.
Data Source
AI summary
A bracket for adjustable-depth mounting of an electrical box relative to a support structure can include a support body and a support arm. The support body can be configured to be secured to the support structure. A fastener can be retained on the support arm and can be adjusted relative to the support arm to move the electrical box to be secured at any of a plurality of depths relative to the support body.