Integrated Support Plate for Multi-Orientation Electrical Box Mounting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical box and conduit support systems struggle to efficiently mount electrical boxes and conduits in various orientations while meeting national and local electrical codes, particularly in terms of spacing requirements.
Innovation Solution
The development of one-piece electrical box and conduit support plates with built-in offsets and hanger tabs that allow for flexible orientation and secure attachment of conduits, using mounting assemblies and hanger clips to suspend from structures, ensuring compliance with electrical code spacing requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional separate mounting methods are used for electrical boxes and conduits, then installation flexibility is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent combines the electrical box support plate and conduit support plate into a single integrated mounting plate. This unified structure provides both electrical box mounting capabilities and conduit support functions in one component, eliminating the need for separate mounting operations and improving installation flexibility while reducing the number of parts to manufacture and install.
2Productivity
If fixed orientation mounting is used, then installation speed increases, but adaptability to different orientations decreases
Solution Approach 1:
The mounting plate incorporates multiple hanger tabs positioned at different locations and angles on the plate. These tabs can be bent to different orientations and lengths to accommodate various mounting scenarios - whether the electrical box needs to be mounted vertically, horizontally, or at angles, and whether conduits need to approach from different directions. This dynamic adaptability allows installers to configure the plate for different orientations without requiring multiple specialized plates.
3Device complexity
If conduit support is provided separately from electrical box mounting, then structural simplicity is maintained, but spacing compliance becomes difficult
Solution Approach 1:
The integrated mounting plate includes pre-formed conduit support features (such as conduit clips, straps, or attachment points) that are built into the plate structure during manufacturing. These conduit support elements are positioned at predetermined distances from the electrical box mounting location, ensuring that conduits will be supported within the required spacing distances specified by electrical codes. This preliminary positioning eliminates the need for separate measurements and adjustments during installation.
4Ease of manufacture
If multiple separate components are used for mounting, then ease of manufacture is improved, but installation time increases
Solution Approach 1:
The integrated mounting plate combines multiple functions (electrical box support, conduit support, and hanging/mounting capabilities) into a single manufactured component. While the manufacturing process for the integrated plate may be slightly more complex than simple stamping, it eliminates the need to manufacture, inventory, and assemble multiple separate plates and accessories. The single-component design reduces installation time by eliminating multiple mounting steps and allowing electricians to attach both the electrical box and conduit supports in one operation.
Data Source
AI summary
The present disclosure provides improved electrical box and conduit support plates that allow for central mounting of an electrical box to a support plate and mounting of electrical conduits for suspended installations in various orientations. The support plate includes a body having a plurality of built-in offsets, a plurality of built-in hanger tabs, and a plurality of clip mounting apertures that may be arranged as pairs. Each built-in offset preferably has two side walls extending from the body and a mounting arm between the side walls. Each mounting arm includes a plurality of clamp mounting apertures used to attach a conduit clamp to the mounting arm. Each of the plurality of built-in hanger tabs are preferably bendable relative to the body. Box and conduit support kits that includes a body and a plurality of hanger clips are also provided.