Adjustable-Depth Electrical Box Bracket With Interior Fastener Access
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Solution Overview
Problem
Existing solutions fail to provide a flexible and efficient method for securing electrical boxes at different depths relative to support structures, such as ceilings or walls, which is necessary for aligning electrical boxes with internal surfaces like drywall or ceiling tiles.
Innovation Solution
A bracket system with a support body and adjustable support arms that allow for rotational adjustment of fasteners, enabling the electrical box to be secured at various depths by rotating the fasteners relative to the support arms, which are either integrally formed or separately secured to the electrical box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed-depth mounting bracket is used, then the installation process is simple, but the electrical box cannot be adjusted to different depths to align with internal surfaces
Solution Approach 1:
The bracket incorporates a movable support arm with a fastener that can be adjusted along the arm's length. The support arm rotates relative to the support body, allowing the electrical box to be positioned at different depths while maintaining a secure connection. This dynamic adjustment mechanism resolves the contradiction by enabling depth variability without requiring multiple fixed-depth brackets.
Solution Approach 2:
The bracket is divided into distinct functional components: a support body for mounting to the support structure, a support arm for holding the electrical box, and a fastener for securing the box to the arm. This segmentation allows each component to be optimized independently and facilitates the adjustment mechanism, resolving the complexity concern while enabling adaptability.
2Ease of operation
If the fastener is accessible from the exterior for adjustment, then adjustment is easy, but it interferes with wires or structural features behind the electrical box
Solution Approach 1:
Instead of allowing exterior access to the fastener, the design enables adjustment from the interior of the electrical box. The fastener is positioned such that its adjustment mechanism can be accessed through the electrical box opening, reversing the typical access direction. This resolves the contradiction by eliminating exterior interference while maintaining ease of operation through interior access.
3Reliability
If the electrical box is securely mounted to prevent movement, then mounting reliability is high, but depth adjustment after installation becomes difficult
Solution Approach 1:
The bracket employs a dynamic fastening system where the support arm can rotate relative to the support body while the fastener maintains secure engagement. This allows the electrical box to be firmly mounted in any desired position and then adjusted to different depths by rotating the support arm, without compromising mounting reliability. The secure mounting and adjustability are achieved through the same dynamic mechanism.
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 the electrical box's mounting depth after installation, ensuring flush alignment with internal surfaces while maintaining accessibility and minimizing interference with wires or structural features.
Implementation Method 1
The support arm can be configured to hold the fastener relative to the electrical box, so that the adjustment of the fastener relative to the support arm 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.