Electrical Box Stand With Ribs For Concrete Form Positioning
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Solution Overview
Problem
The existing methods for installing electrical boxes in concrete structures are inefficient due to the need for tying them to reinforcing bars, which increases installation time and cost, and the challenge of routing electrical tubing around obstacles, leading to potential damage and exposed areas after concrete hardening.
Innovation Solution
An electrical box stand assembly that supports the electrical box at predetermined distances from the concrete form using a base and extensions with ribs and slots, allowing for minimal tubing bending and secure positioning without tying to reinforcing bars, accommodating varying concrete slab thicknesses and reducing the need for multiple box types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical boxes are tied to reinforcing bars for positioning, then the electrical boxes can be securely positioned in the concrete form, but additional time is required for the tying action and the cost of installation increases
Solution Approach 1:
The patent introduces an intermediary positioning system consisting of a base plate with positioning protrusions that engage with corresponding recesses in the concrete form. This intermediary mechanism eliminates the need for manual tying to rebars while maintaining secure positioning, thereby reducing installation time and labor costs.
Solution Approach 2:
The base plate is designed with pre-formed positioning protrusions and engagement features that allow the electrical box to be positioned and secured in a single preliminary action rather than requiring multiple tying steps. The positioning elements are pre-configured to match the concrete form geometry, enabling rapid installation.
2Ease of operation
If electrical boxes are tied to rebars, then positioning is achieved, but it is necessary to find rebar at the proper height and location not being used for another purpose
Solution Approach 1:
The base plate design provides a universal positioning solution that works with various concrete form configurations regardless of rebar placement. The positioning protrusions are designed to engage with standard concrete form features, making the system adaptable to different slab thicknesses and reinforcement patterns without requiring specific rebar arrangements.
3Productivity
If post-tensioned cables are used instead of rebars, then structural integrity is increased and construction time is reduced, but there are fewer elements to tie electrical boxes to
Solution Approach 1:
The base plate serves as an intermediary positioning system that does not depend on the presence of rebars or post-tensioned cables. It engages directly with the concrete form structure, providing a reliable positioning mechanism that works equally well with post-tensioned construction methods where traditional rebar tying is not feasible.
4Ease of manufacture
If electrical boxes rest on the concrete form surface, then installation is simplified, but an exposed area remains after concrete hardening requiring patching
Solution Approach 1:
The base plate is designed to be fully embedded in the concrete through the positioning protrusions that engage with the form, allowing the concrete to self-support the electrical box without requiring additional patching or repair work. The design ensures complete integration with the concrete structure, eliminating exposed areas.
5Device complexity
If the electrical box hub is at the bottom resting on the form, then the box structure is simplified, but electrical tubing must bend down to the hub creating difficulty in routing around obstacles
Solution Approach 1:
The base plate elevates the electrical box hub vertically from the concrete form surface, creating additional vertical space for tubing routing. This dimensional change allows electrical tubing to connect to the hub without excessive bending and facilitates easier routing around obstacles such as rebars and post-tensioned cables embedded in the concrete.
Data Source
AI summary
A stand for an electrical box is provided to maintain an electrical box having at least one hub a predetermined distance from a concrete form prior to and during the concrete being poured. The stand has extensions with ribs thereon at different longitudinal positions from the base permitting the electrical box to be supported by the stand at different heights with respect to the concrete form to permit access to the hubs of the electrical box with electrical tubing and to accommodate concrete slabs of different thicknesses using the same height of electrical box. The electrical box and stand assembly have a locking mechanism to lock the electrical box to the stand at the selected predetermined distance from the form. The locking mechanism has hooks which engage indentations on mounting tabs of the electrical box. The mounting tabs have grooves which guide the hooks to the indentations. The stand can be attached to the cement form during building construction to maintain the electrical box at the predetermined distance above the cement form.