Gangable Electrical Box With Adjustable Mounting Bracket
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Solution Overview
Problem
Existing electrical boxes lack flexibility in accommodating various electrical connections and mounting configurations, limiting their adaptability to different installations and wall thicknesses.
Innovation Solution
A gangable electrical box with a removable partition plate and adjustable mounting bracket, featuring oversized knockouts and extendable support members that can be adjusted to fit different conduit sizes and wall surfaces, allowing for customizable positioning and support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrical boxes have fixed partition plates and standard-sized knockouts, then manufacturing is simpler, but adaptability to different electrical connections and wall configurations is reduced
Solution Approach 1:
The partition plate is divided into multiple sections that can be independently removed or repositioned. The knockout system is segmented with multiple knockout locations that can be selectively removed, allowing customization of the box configuration to match specific electrical connection requirements while maintaining a relatively simple overall box structure.
Solution Approach 2:
The partition plate is designed to be movable rather than fixed, allowing it to be repositioned along the box to accommodate different wall thicknesses and electrical device positions. The knockout system allows selective removal of specific sections, providing dynamic adaptability without requiring a completely different box design for each application.
2Adaptability or versatility
If electrical boxes have fixed mounting positions, then manufacturing and installation are simpler, but adaptability to different wall thicknesses is reduced
Solution Approach 1:
The mounting bracket incorporates an extendable support member that can be adjusted to different lengths or positions, allowing the electrical box to be mounted at various distances from the wall surface to accommodate different wall thicknesses. This dynamic adjustment capability maintains installation simplicity while providing adaptability to diverse wall configurations.
Solution Approach 2:
The mounting bracket is designed as a separate, adjustable component rather than being integrally fixed to the box. This segmentation allows the support member to be independently adjusted or repositioned to match different installation requirements without affecting the main box structure or requiring complex reconfiguration.
3Adaptability or versatility
If electrical boxes have standard support brackets, then manufacturing is easier, but adaptability to various mounting configurations is limited
Solution Approach 1:
The support bracket is designed as a modular component with distinct sections including a mounting portion and an extendable support member. This segmentation allows each component to be manufactured using standard processes while the combination provides enhanced adaptability. The bracket can be attached to the box and adjusted to various configurations without requiring custom manufacturing for each application.
Solution Approach 2:
The support bracket is designed to perform multiple functions: providing structural support, enabling adjustment for different wall thicknesses, and accommodating various mounting configurations. This multi-functionality is achieved through the extendable support member that can be positioned at different lengths and angles, allowing a single bracket design to serve diverse mounting needs without increasing manufacturing complexity significantly.
Data Source
AI summary
An electrical box assembly includes an electrical box having a removable partition plate that can be positioned between the ends of the electrical box or at the end of the electrical box when two or more of the electrical boxes are ganged together. The electrical box can include a mounting bracket having a body portion attached to a wall of the box for supporting the box during use. A support member is coupled to the mounting bracket and is extendable to a length to contact the opposing wall. The mounting and the support member are independently adjustable with respect to the box.