Hole Saw Electrical Box with Teeth and Resilient Bracket
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Solution Overview
Problem
Existing methods for retrofitting electrical devices or light fixtures into walls require extensive sheetrock removal and complex hole enlargement, making the process time-consuming and difficult to ensure proper installation.
Innovation Solution
An electrical box assembly with a circular design featuring outwardly extending flanges, bosses, and integral teeth on the sidewall, along with an adjustable bracket with resilient legs, which allows for easy installation through a simple circular hole by ripping a path through the drywall and securing the box with clamping action.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If flip out clamps are used to secure the electrical box to the wall, then the box can be attached to the sheetrock, but the hole must be enlarged beyond a simple circular shape to accommodate the clamps
Solution Approach 1:
The attachment function is segmented between the integral teeth (which rip through the sheetrock to create attachment paths) and the flanges (which provide clamping surfaces). This segmentation allows the box to be secured through a simple circular hole without needing to enlarge the hole for clamp accommodation.
Solution Approach 2:
The teeth and flanges are merged into a single integrated structure that is molded as one piece with the box body. This merging eliminates the need for separate clamp components and simplifies the installation process to require only a circular hole.
2Ease of operation
If the electrical box is pushed through the sheetrock with flip out clamps, then the box can be installed, but it becomes difficult to determine whether the clamps are rotated to the proper position
Solution Approach 1:
The resilient legs automatically indicate their engagement status through their physical state. When the legs are engaged with the sheetrock, they assume a specific position that is visually detectable, allowing the installer to verify proper installation without additional tools or complex mechanisms.
Solution Approach 2:
The resilient legs are positioned and shaped to provide visual feedback about their engagement state. The legs' position relative to the box body changes as they engage with the sheetrock, providing a clear visual indicator of proper installation.
3Strength
If a substantial amount of sheetrock is removed to install a standard electrical box, then the box can be securely mounted to studs, but the installation process becomes time-consuming and requires extensive repair work
Solution Approach 1:
The invention extracts the mounting function from the traditional stud-attachment method and creates a new attachment mechanism (teeth and flanges) that works directly with the sheetrock surface. This allows secure mounting without removing large sections of sheetrock or requiring stud access.
Solution Approach 2:
The teeth are pre-formed as integral parts of the box structure, ready to rip through the sheetrock during installation. The flanges are pre-positioned to provide immediate clamping surfaces, eliminating the need for preliminary sheetrock removal or repair work.
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
Enables quick and secure mounting of electrical devices and light fixtures with minimal prep work, requiring only a circular hole and providing all necessary hardware for secure attachment to the wall, accommodating conventional fixtures within its weight rating.
Implementation Method 1
An elongated bracket with resilient legs is adjustably connected to the back wall of the box
Implementation Method 2
Teeth are provided along the outer sidewall of the box in alignment with and extending from each boss to the back wall. After a hole is made in the drywall, the teeth rip a path for the bosses as the electrical box assembly is pushed into the hole
Implementation Method 3
The fasteners of the adjustment arrangement are tightened to narrow the clearance between the box and the bracket and secure the box to the wall. The box is held secure to the wall by the clamping action of the bracket legs and flange on the drywall or similar wall covering
Data Source
AI summary
An electrical box assembly for mounting an electrical device or fixture on a wall. The electrical box assembly includes a box having a back wall and a sidewall defining an enclosure, and flanges and bosses extending outward from the sidewall. Teeth are provided along the outer sidewall of the box in alignment with and extending from each boss to the back wall. An elongated bracket with resilient legs is adjustably connected to the back wall of the box. After a hole is made in the drywall, the teeth rip a path for the bosses as the electrical box assembly is pushed into the hole. An adjustment arrangement including fasteners is provided for adjusting the distance of the bracket with respect to the box and securing the box to the wall. The clamping action of the bracket legs and flange on the drywall hold the electrical box assembly secure to the wall.