Adjustable-Depth Electrical Box Mounting for Flush Wall Finishes
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Solution Overview
Problem
Existing electrical box mounting systems fail to accommodate varying depths of wall support structures, leading to difficulties in achieving a flush alignment with wall coverings, particularly when different types of wall materials and depths are involved.
Innovation Solution
An electrical-box-and-bracket assembly with adjustable fasteners and a bracket that includes a support body with arms and a mounting flange, allowing for adjustable depth positioning of the electrical box relative to the support structure, using threaded fasteners to adjust the box's depth and an adjustable far side support to ensure flush alignment with wall coverings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional fixed-depth electrical box mounting systems are used, then installation is simple, but the electrical box cannot accommodate varying depths of wall support structures and achieve flush alignment with wall coverings
Solution Approach 1:
The mounting system transitions from a fixed-depth configuration to a dynamic, adjustable-depth system. The electrical box is mounted on a bracket with threaded fasteners that allow the box to be positioned at different depths relative to the wall support structure, enabling adaptation to various wall covering depths while maintaining a relatively simple overall structure.
Solution Approach 2:
The system allows changing the depth parameter of the electrical box mounting by adjusting the position of the box on the bracket. The threaded fasteners enable precise adjustment of the box's depth position, transforming a static parameter into a variable one that can be customized for different installation scenarios.
2Manufacturing precision
If extension rings are used to achieve flush alignment, then alignment is possible, but installation time and complexity increase
Solution Approach 1:
The solution extracts the depth adjustment functionality from the electrical box itself and relocates it to the mounting bracket system. By separating the adjustment mechanism from the box, the system achieves precise flush alignment capability without requiring additional extension rings or complex modification of the box structure, thereby reducing installation time.
Solution Approach 2:
The bracket is pre-configured with threaded fasteners and adjustment mechanisms that enable depth adjustment before final installation. This preliminary preparation allows installers to achieve precise flush alignment during the initial mounting process rather than requiring subsequent adjustments or additional components like extension rings.
3Adaptability or versatility
If adjustable fasteners are implemented, then depth adjustment is enabled, but the mounting system becomes more complex
Solution Approach 1:
The mounting system is segmented into distinct functional components: the bracket, the threaded fasteners, and the electrical box. This segmentation allows the adjustable fasteners to be independently designed and optimized for depth adjustment functionality without complicating the overall system. Each component remains relatively simple, but their combination provides versatile depth positioning capability.
Data Source
AI summary
An electrical-box-and-bracket that can include a bracket including a support body, with a bracket opening, and first and second support arms extending from the support body on opposing sides of the bracket opening. An electrical box can have a front opening and can be positioned within the bracket opening. The assembly can further include a set of adjustable fasteners, including first and second box adjustment fasteners and an adjustable far side support. The first and second box adjustment fasteners can extend through a rear wall of the electrical box and to the first and second support arms and can be accessible for selectively adjusting the distance between the bracket opening of the bracket and the front opening of the electrical box. The adjustable far side support can extend through the rear wall of the electrical box and can be accessible for adjustably supporting the electrical box.