Electrical Box Support Bracket for Hollow Core Block
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Solution Overview
Problem
Existing methods for mounting electrical boxes in concrete and block walls are inadequate, as they often require cement, mortar, or fasteners that cannot easily penetrate these materials, compromising structural integrity and stability.
Innovation Solution
A support bracket made from sheet steel or other materials, featuring a tab for clipping onto the electrical box and a spring-biased flange for securing it within a hollow core building block, allowing for secure positioning without the need for cement, mortar, or fasteners during construction, with the option to separate the flange post-installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If mechanical fasteners are used to secure the electrical box, then the electrical box is firmly fixed in place, but the fasteners cannot be easily driven into concrete or block walls, compromising installation feasibility
Solution Approach 1:
The support device is divided into multiple functional segments: a support body for attachment to the electrical box, outwardly extending arms for engagement with the block cavity, and spring elements for applying securing force. This segmentation allows each component to perform its specific function independently, enabling secure fixation without requiring fasteners to penetrate the wall material.
Solution Approach 2:
The support device acts as an intermediary between the electrical box and the block wall. Instead of directly fastening the electrical box to the wall with screws or nails, the support device engages the electrical box through its body and secures it within the block cavity through its arms, mediating the connection without requiring penetration of the wall material.
2Stability of the object's composition
If cement or mortar is used to hold the support in place, then the electrical box is secured in the wall, but the support interferes with the structural integrity of the joint and requires additional materials
Solution Approach 1:
The support device extracts the need for cement or mortar from the mounting process. By using spring-biased arms that engage the electrical box within the block cavity, the device eliminates the requirement for additional binding materials that would interfere with wall joints or compromise structural integrity.
Solution Approach 2:
The spring elements provide self-service by automatically applying securing force to hold the electrical box in position. The elastic bias of the springs creates continuous contact pressure that maintains the electrical box's position without requiring external materials like cement or mortar, allowing the device to secure itself within the block cavity.
3Ease of operation
If sheet metal forms with tabs are used to hold the electrical box, then the box is positioned during construction, but the device requires positioning between joints which interferes with structural integrity
Solution Approach 1:
The support device transitions from a two-dimensional tab configuration to a three-dimensional structure with outwardly extending arms that engage the block cavity. This dimensional change allows the device to be positioned within the hollow core of the block rather than between joints, eliminating interference with wall joint integrity while maintaining ease of electrical box positioning.
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
The solution provides a stable and secure mounting system for electrical boxes in hollow core building blocks, ensuring the boxes remain fixed during construction and use, while avoiding interference with the structural integrity and allowing for easy removal of the flange post-installation.
Implementation Method 1
A spring member having a first end coupled to the second side edge of the body and a first leg portion extending away from the body. A second contact end of the spring member extends towards the flange. The second contact end is spring biased toward the flange and is positioned to contact an inner surface of the block
Data Source
AI summary
An electrical box support is provided for coupling to the side wall of an electrical box to support the electrical box in an opening formed in a hollow core building block. The support has a flange at the front edge and tab at a front edge that clips onto the side wall of the electrical box. A spring member extends from a rear side edge and curls toward the front edge. The spring member has an end that is directed toward the front edge and spaced from the flange a distance to contact the inner surface of the block while the flange contacts the outer surface of the block. The tab at the front edge of the support has a hook for engaging an inner edge of the electrical box to couple the support to the electrical box and to prevent sliding of the support on the electrical box.