Electrical Box Hanger Assembly with Integrated Fastener Storage
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Solution Overview
Problem
Existing electrical box mounting systems are complex and cumbersome, requiring multiple fasteners and components, making it difficult for installers to securely mount ceiling fixtures while ensuring the load is borne by the supporting device and not the electrical box, especially when working overhead.
Innovation Solution
An adjustable mounting bar and electrical box assembly that includes all necessary hardware, featuring sliding tubular members with end flanges for secure attachment to joists, a clamp for adjusting the electrical box position, and storage receptacles for fasteners, ensuring the load is borne by the clamp and mounting bars, simplifying the installation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate fasteners and components are used for mounting electrical boxes to ceiling joists, then the mounting can be securely achieved, but the installation process becomes complex and time-consuming requiring multiple assembly steps while working overhead
Solution Approach 1:
The patent combines multiple separate mounting components into a single integrated mounting assembly that includes the electrical box, mounting brackets, and fasteners as one pre-assembled unit. This allows the entire mounting system to be installed in a single operation rather than requiring multiple separate assembly steps, thereby reducing installation complexity while maintaining secure mounting through the integrated design of all components working together
2Adaptability or versatility
If multiple separate fasteners are provided in separate packaging, then all necessary hardware can be supplied, but the installer must manage multiple loose parts while working overhead creating difficulty in the installation process
Solution Approach 1:
The patent integrates all necessary fasteners and mounting hardware into the single pre-assembled mounting assembly, eliminating the need for separate packaging of multiple fasteners. The fasteners are permanently attached to the mounting brackets or electrical box in the correct positions, allowing the installer to simply attach the entire assembly to the ceiling joist without managing loose parts, thereby improving ease of operation while maintaining hardware completeness
3Strength
If traditional mounting methods are used requiring assembly of multiple components overhead, then proper load distribution can be achieved, but the installer faces challenging working conditions requiring precise assembly while reaching upwards
Solution Approach 1:
The patent performs the complex assembly of multiple mounting components and fasteners in advance during manufacturing, creating a pre-assembled mounting unit with all components properly positioned and secured. This preliminary action eliminates the need for the installer to perform precise assembly operations while working overhead, allowing them to simply attach the complete assembly to the ceiling joist, thereby improving ease of operation while maintaining load bearing capacity through the pre-engineered component arrangement
Data Source
AI summary
An electrical box hanger assembly for hanging an electrical fixture from a ceiling. All hardware required for mounting the electrical device is included with the assembly. An adjustable mounting bar includes sliding tubular members with end flanges for spanning between adjacent overhead joists. An electrical box is connected to the adjustable mounting bar by a one-piece mounting bracket and a single box mounting fastener. The mounting bracket includes integral tensioner tangs on the mounting bracket prevent backing out of the box mounting fastener after it is secured in place. Bar fasteners are used to securely fasten the mounting bar to the joists. Load bearing device fasteners used to secure the mounting ring of an electrical fixture to the electrical box. Oversize openings are provided in the top wall of the electrical box to ensure that the suspended load is borne by the clamp and mounting bar and not the electrical box.