Foldable Electrical Box Bracket for Faster Stud Mounting
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Solution Overview
Problem
The existing methods for mounting electrical boxes in building structures are time-consuming and require accessing elevated or difficult-to-reach components, leading to inefficiencies and safety concerns.
Innovation Solution
A unitary, one-piece mounting bracket that can be deformed from a planar configuration to form a box section and stud sections, facilitating easy attachment to building studs and enabling quick installation of electrical boxes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional mounting methods are used for electrical boxes, then the installation can be completed, but the process is time-consuming and requires accessing elevated or difficult-to-reach components
Solution Approach 1:
The mounting bracket is divided into multiple planar elements that can be independently positioned and then folded together to form the three-dimensional box structure, enabling quick assembly without complex tools or elevated access
Solution Approach 2:
The bracket transitions from a static flat configuration to a dynamic three-dimensional structure through folding actions, allowing the installer to easily transform the mounting device in-hand without requiring elevated access or specialized tools
2Reliability
If traditional mounting methods are used for electrical boxes, then the box can be secured, but the process requires accessing components at elevated heights which creates safety concerns
Solution Approach 1:
The bracket is pre-configured in a flat, easy-to-handle state that can be prepared and positioned at ground level, then folded into its mounting configuration once in position, eliminating the need to perform complex assembly operations at elevated heights
Solution Approach 2:
The foldable bracket serves as an intermediary that transforms from a manageable flat state to a secure mounting structure, allowing the installer to work from a safe position while still achieving reliable mounting through the bracket's inherent folding mechanism
3Ease of manufacture
If a unitary one-piece bracket is used, then manufacture is facilitated and efficiency is improved, but the bracket must be deformable from planar to three-dimensional configuration
Solution Approach 1:
The bracket incorporates hinge joints that enable smooth transformation from a simple planar configuration to a three-dimensional mounting structure, maintaining manufacturing simplicity while achieving the required functional complexity through controlled flexibility
Solution Approach 2:
The bracket's physical configuration changes from a flat two-dimensional arrangement to a folded three-dimensional structure through controlled deformation at hinge points, allowing a single-piece design to achieve both manufacturing ease and functional 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 mounting bracket significantly reduces installation time, enhances safety by allowing for secure attachment at a consistent, accessible height, and offers cost savings for electrical contractors by streamlining the installation process.
Implementation Method 1
The mounting bracket is deformable from the initial planar configuration to configure the box elements in a rectangular configuration, to thereby form the box section in a tubular configuration
Data Source
AI summary
An improved arrangement for mounting an electrical box comprises a unique, unitary mounting bracket. Notably, the mounting bracket has an initial planar configuration, comprising a single metallic component, thus facilitating convenient manufacture, and efficient use. The mounting bracket comprises a box section formed from four parallel, box elements initially arranged in co-planar relationship with each other. The mounting bracket further comprises a pair of stud sections, respectively extending from a pair of the box elements which are spaced from each other by an intermediate one of the box elements.