Adjustable Electrical Box Mounting for Flush Wall Alignment
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Solution Overview
Problem
Existing electrical boxes are difficult to reposition accurately on walls with varying thicknesses, requiring complex and costly adjustments that involve removing and re-fastening fastening devices, and often result in loose fittings.
Innovation Solution
An electrical box assembly with a bracket and threaded fastener system that allows for adjustable positioning relative to a mounting structure, using a channel and guide structures for secure fastening and easy repositioning without additional apertures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional fastening devices are used to secure electrical boxes to wall studs, then the electrical box can be firmly attached to the mounting structure, but repositioning requires complete removal and re-fastening which is time-consuming and requires additional apertures
Solution Approach 1:
The patent applies the dynamics principle by making the mounting system adjustable rather than fixed. The bracket includes a slot that allows the electrical box to be repositioned along the mounting structure without complete removal. The fastening mechanism transitions from a static connection to a dynamic, adjustable connection that maintains security while enabling movement, directly resolving the contradiction between firm attachment and repositioning ease.
Solution Approach 2:
The mounting system is segmented into distinct components: a bracket attached to the mounting structure, a slot in the bracket, and the electrical box with its own mounting holes. This segmentation allows the electrical box to be independently repositioned within the slot without affecting the bracket's attachment to the mounting structure, enabling time-efficient repositioning without additional apertures in the mounting structure.
2Adaptability or versatility
If adjustable outlet boxes with brackets are used to accommodate varying wall thicknesses, then the box can be positioned flush with the wall surface, but the bracket design becomes complex increasing production costs
Solution Approach 1:
The bracket is designed with a universal slot that serves multiple functions: it provides adjustment for varying wall thicknesses, guides the repositioning movement, and maintains structural support. This single multi-functional slot replaces what would otherwise require multiple adjustment mechanisms, achieving adaptability while maintaining design simplicity and reducing production costs.
Solution Approach 2:
The system allows for parameter changes in the position of the electrical box along the slot to accommodate different wall thicknesses. By changing the positional parameter rather than redesigning the bracket structure, the system achieves adaptability with minimal complexity. The slot's geometry is optimized to provide the necessary range of motion without requiring complex mechanisms.
3Ease of operation
If the electrical box is repositioned by removing and re-fastening fastening devices, then the box can be moved to a new position, but additional apertures must be formed in the mounting structure
Solution Approach 1:
The patent introduces an additional dimensional element by adding a slot that extends perpendicular to the mounting structure's surface. This slot provides a third dimension for adjustment, allowing the electrical box to be repositioned along the slot's length without creating additional apertures in the mounting structure itself. The repositioning occurs within the existing bracket structure rather than requiring modifications to the mounting structure.
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
Facilitates easy and secure repositioning of electrical boxes to achieve flush mounting, reducing installation time and costs by allowing adjustments without complex redesigns.
Implementation Method 1
A threaded fastener is configured to be rotatably received in the channel and threadingly received in the at least one guide structure to selectively adjust a position of the bracket relative to the electrical box with respect to an axial direction of the threaded fastener
Data Source
AI summary
An electrical box assembly is disclosed including an electrical box having at least one sidewall, the sidewall including a channel formed therein to receive a threaded fastener. A mounting bracket is provided that is configured to be attached to a support member. The mounting bracket is operably engaged with the threaded fastener to facilitate an adjustment of the mounting bracket with respect to the electrical box, and consequently adjust the electrical box with respect to the support member.