Adjustable Electrical Box Bracket for Flush Mounting Depth

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Solution Overview

Problem

Existing technologies lack a practical solution for supporting electrical boxes at different depths relative to support structures, such as ceilings or walls, which is necessary for flush mounting with internal surfaces.

Innovation Solution

A bracket assembly with a support body and adjustable support arms that allow for the securement of an electrical box at various depths by using a rotatable fastener that adjusts the box's position relative to the support body.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a fixed mounting bracket is used to secure an electrical box, then the electrical box is firmly supported, but the mounting depth cannot be adjusted to achieve flush mounting with internal surfaces

Engineering Contradiction:

Improvemounting depth adjustabilityVSAvoidbracket structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The bracket employs a dynamic adjustment mechanism where a support arm can be positioned at multiple discrete locations along the electrical box, allowing the mounting depth to be adjusted. The support arm is retained at selected positions through engagement features that allow both adjustment and stable support, resolving the contradiction between adjustability and structural simplicity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The bracket structure is segmented into a main body and an adjustable support arm component. This segmentation allows the support arm to be independently positioned at different locations to achieve various mounting depths, while the main body remains fixed to the support structure, providing both adaptability and structural clarity.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If the support arm extends further to allow greater depth adjustment, then more mounting positions are available, but the bracket interferes more with surrounding structures

Engineering Contradiction:

Improvemounting depth rangeVSAvoidinterference with surrounding structures

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The support arm is designed with varying lengths or adjustable extension points that allow it to reach different depths as needed. The arm can be positioned to extend only as far as necessary for the specific mounting requirement, minimizing interference with surrounding structures while still providing the needed depth adjustment range.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If multiple fasteners are used to secure the support arm at different positions, then accurate depth adjustment is achieved, but the installation and adjustment process becomes more complex

Engineering Contradiction:

Improvemounting depth precisionVSAvoidinstallation simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The bracket incorporates self-retaining features such as spring-loaded clips, cam locks, or snap-fit mechanisms that automatically secure the support arm at selected positions without requiring multiple fasteners. The operator simply positions the support arm at the desired location, and the self-service mechanism maintains it there, achieving precise depth adjustment while keeping installation simple.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS12305802B2Bracket for adjustable-depth mounting of electrical boxes

Publication Date: 2025.05.20 ERICO INTERNATIONAL CORP

AI summary

A bracket for adjustable-depth mounting of an electrical box relative to a support structure can include a support body and a support arm. The support body can be configured to be secured to the support structure. A fastener can be retained on the support arm and can be adjusted relative to the support arm to move the electrical box to be secured at any of a plurality of depths relative to the support body.