Electrical Box Mounting Rail With Tool-Less Adjustable Locking

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Solution Overview

Problem

Existing construction standards require electrical boxes to be supported at specific locations and heights, but existing support systems lack efficient and tool-less methods for secure attachment and adjustment.

Innovation Solution

A box support system with a rail design and mounting interfaces that allow for manual, tool-less connection and adjustment of support attachments, enabling secure and interchangeable support of electrical boxes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If traditional support systems are used for electrical boxes, then secure attachment is achieved, but installation requires tools and is complex

Engineering Contradiction:

Improvemanual tool-less connectionVSAvoidsecure attachment

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The mounting interface uses nested channels where a first channel and second channel are positioned one inside the other, creating an interlocking structure that provides secure attachment while allowing manual assembly through simple insertion movements

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The mounting interface is divided into separate components including first and second channels, interface arms, and engagement features that can be independently positioned and assembled, enabling tool-less connection while maintaining structural integrity

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If fixed support structures are used, then stability is achieved, but adjustability is limited

Engineering Contradiction:

Improveadjustable support positionsVSAvoidstable support

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The support system incorporates adjustable features that allow the electrical box support position to be modified after installation, while the nested channel structure maintains stability during each adjusted configuration through interlocking engagement features

Inventive Principle:

Principle #15Dynamics

3Reliability

If complex mounting interfaces are used, then secure connection is achieved, but device complexity increases

Engineering Contradiction:

Improvesecure connectionVSAvoidmounting interface structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The mounting interface design uses standardized first and second channels with complementary engagement features that can accommodate various support configurations and electrical box types, reducing overall system complexity through a universal connection approach

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12294208B2Support system for electrical boxes

Publication Date: 2025.05.06 ERICO INTERNATIONAL CORP

AI summary

A mounting system for a first support and a second support for electrical components can include a first mounting interface and a second mounting interface. The first mounting interface can include a first channel, and a first insertion slot extending from inside of the first channel to outside of the first channel. The second mounting interface can include a second channel and a first interface arm, and a second interface arm. The second channel can be configured to nest within the first channel. The first interface arm can extend through the first insertion slot when the second channel is nested within the first channel. The second interface arm can be spaced laterally from the second channel and can engage an outside surface of the first channel when the second channel is nested within the first channel.