Telescoping Electrical Box Support Assembly for Fastener-Free Stud Mounting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrical box support struts require different types for varying box depths and are difficult to install due to pre-bent flanges, leading to shipping and inventory issues, as well as challenges in maintaining alignment and securing the strut to studs without additional fasteners.
Innovation Solution
A telescoping electrical box support assembly with detachable engaging tabs that include compressible members and opposing engagement members, allowing for adjustable coupling with studs of varying widths and depths, enabling secure mounting without additional fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different types of struts are used for different box depths, then proper mounting for each box depth is achieved, but shipping and inventory complexity increases
Solution Approach 1:
A single strut design with adjustable engaging tabs can accommodate multiple box depths and stud types, replacing the need for multiple specialized strut types. The engaging tabs can be positioned at different locations to adapt to varying box depths, while the same strut maintains compatibility with both metal and wood studs through its universal engagement mechanism.
2Strength
If pre-bent flanges are used for stud mounting, then secure attachment to studs is achieved, but adaptability to different stud types and box depths is reduced
Solution Approach 1:
The engaging tabs are designed to be movable and repositionable along the strut rather than fixed in predetermined locations. This dynamic configuration allows the tabs to be adjusted to different positions depending on the box depth and stud type, providing both strong attachment and high adaptability without requiring multiple specialized strut types.
3Reliability
If additional fasteners are used to secure the strut to studs, then secure mounting is achieved, but installation time and complexity increase
Solution Approach 1:
The engaging tabs are designed to self-align and self-secure to the studs through their geometric configuration and elastic properties. When the strut is positioned against the stud, the tabs automatically engage with the stud surface through elastic deformation and geometric interlocking, eliminating the need for separate fastening operations and reducing installation time while maintaining secure mounting.
4Ease of operation
If the installer must hold the strut with one hand and fasten with the other, then fastening can be performed, but alignment accuracy and installation efficiency decrease
Solution Approach 1:
The engaging tabs are designed to self-align with the stud surface through their elastic properties and geometric configuration. When the strut approaches the stud, the tabs automatically orient themselves perpendicular to the stud surface through elastic deformation, providing precise alignment without requiring the installer to manually position or hold the strut in the correct orientation.
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
Facilitates quick field formation to accommodate different box depths and secure mounting on any stud surface, reducing installation time and inventory complexity while maintaining alignment and stability.
Implementation Method 1
a first compressible member extending from either the first engagement member or the second engagement member. The first compressible member is compressible in a second direction D2 opposite that of the first direction D1
Data Source
AI summary
An electrical box support assembly for mounting an electrical box between a pair of studs is provided. The electrical box support assembly includes, but is not limited to, a pair of telescoping overlapping struts and a pair of engaging tabs detachably coupled with each end of the pair of telescoping overlapping struts. Each strut has a face to which the electrical box may be secured. Each of the pair of engaging tabs includes a first engagement member for primarily engaging a closed face of one of the studs and a side engagement member connected generally perpendicular with the first engagement member. Each end of the pair of telescoping overlapping struts may be detachably coupled at one of two positions on each engaging tab in order to accommodate electrical boxes of varying depths.