Electrical Box Support with Deformable Retention for Concrete Block Mounting
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Solution Overview
Problem
Mounting electrical boxes in concrete structures is challenging due to the lack of suitable fasteners and the need for solutions that do not compromise the structural integrity of hollow concrete blocks, as traditional fasteners like nails and screws cannot be easily driven into concrete.
Innovation Solution
A support system comprising a planar body with a flange and a retention member that can be deformed to securely hold an electrical box in place within a concrete block, using a sheet metal design with flanges that stabilize and orient the box, and a retention member that contacts the block's edge to prevent movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mechanical fasteners (nails, screws) are used to mount electrical boxes, then the electrical box can be securely fixed, but these fasteners cannot be easily driven into concrete blocks
Solution Approach 1:
The patent introduces a support assembly as an intermediary component between the electrical box and the concrete block. This support assembly includes a body with retention members that can be deformed to engage with the concrete block, while the electrical box attaches to the support assembly. This mediator enables mounting in concrete without requiring direct fastening of traditional mechanical fasteners into the concrete block.
Solution Approach 2:
The retention members of the support assembly are designed to change their physical state from a deformable configuration during installation to a locked configuration that provides secure retention. The retention members can be deformed to expand or change shape to engage with the concrete block, then locked in place to provide reliable mounting security.
2Reliability
If sheet metal forms with tabs and cement are used to mount electrical boxes, then the electrical box can be held in position, but the device must be installed between joints which interferes with structural integrity
Solution Approach 1:
The support assembly is divided into distinct functional components: a body portion that attaches to the electrical box, retention members that engage with the concrete block, and positioning features that ensure proper alignment. This segmentation allows each component to perform its specific function independently, enabling the electrical box to be mounted on the face of the concrete block rather than between joints.
Solution Approach 2:
The support assembly serves as an intermediary that transfers the mounting load from the electrical box to the concrete block face, eliminating the need to install mounting devices between joints. The retention members engage with the concrete block face directly, preserving the structural integrity of the joints while providing secure mounting.
3Reliability
If cement or mortar is used to hold the support in place, then the electrical box can be secured, but the installation process becomes more complex and time-consuming
Solution Approach 1:
The retention members are designed to be self-retaining through their deformable characteristics. During installation, the retention members are deformed to engage with the concrete block, and their elastic or plastic deformation provides automatic retention without requiring additional cement or mortar. The support assembly essentially installs and secures itself through the mechanical deformation and locking of the retention members.
Solution Approach 2:
The invention extracts the cement or mortar bonding function from the mounting system and replaces it with mechanical retention through deformable retention members. This eliminates the need for additional materials and simplifies the installation process to purely mechanical steps, significantly improving installation speed while maintaining secure mounting.
4Manufacturing precision
If flanges are added to orient the electrical box, then the positioning accuracy improves, but the device complexity increases
Solution Approach 1:
The flange for positioning and the retention members for securing are merged into a single integrated support assembly body. The flange portion extends from the body and provides positioning accuracy by contacting the concrete block face, while the retention members are integrated into the same structure. This merging achieves precise positioning without requiring separate positioning devices, thus limiting the increase in complexity.
Solution Approach 2:
The support assembly body serves multiple functions simultaneously: it attaches to the electrical box, provides positioning through the flange, and secures the assembly through the retention members. This multi-functionality reduces the need for separate components for each function, achieving positioning accuracy without proportionally increasing device complexity.
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 support system effectively secures electrical boxes in concrete structures during construction and use, preventing movement and ensuring structural integrity by using deformable retention members that engage the block's surface, allowing for secure installation without compromising the block's integrity.
Implementation Method 1
At least a portion of the retention member is deformable from a first configuration to a second configuration in which the portion of the retention member is positioned away from the body and contacts the block
Data Source
AI summary
A support is provided for mounting an electrical box in an opening formed in a block. The support includes a planar body configured to be coupled to a first side wall of the electrical box. The body includes at least one side edge. The support further includes a flange coupled to the first side edge of the body and extends substantially perpendicular to a plane of the body. The flange is configured to contact an outer surface of the block and to orient an outer edge of the electrical box relative to the block. The support further includes a retention member that is coupled to the body. The retention member has an end. At least a portion of the retention member is movable from a first configuration to a second configuration in which the portion of the retention member is positioned away from the body and contacts the block.