Mounting Bracket With Foldable Far Side Support
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Solution Overview
Problem
Existing electrical box mounting brackets often fail to provide adequate support to both sides of the electrical box, leading to potential movement during use, and there is a need for improved support mechanisms that can accommodate varying wall cavity depths.
Innovation Solution
A mounting bracket with an extendable portion that can bend outwardly to contact the inner surface of an opposing wall, featuring a body member that lies flat against the electrical box and a support member that can be folded to increase length, allowing for secure attachment to both sides of the electrical box and accommodating different wall spacings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single mounting bracket is used to support one side of the electrical box, then the bracket structure is simple, but the electrical box experiences movement during use due to insufficient support
Solution Approach 1:
The mounting bracket is divided into two separate brackets, each supporting one side of the electrical box. This segmentation allows each bracket to be independently optimized and provides balanced support on both sides, eliminating the movement issue while keeping individual bracket structures simple.
Solution Approach 2:
The mounting bracket combines multiple functional elements into a single component: the body member for attaching to the electrical box, the support member for extending to the wall, and the extension member for adjusting to different wall depths. This merging provides complete support functionality in one integrated bracket.
2Device complexity
If a fixed-length support bracket is used, then the bracket structure is simple, but it cannot accommodate wall cavities of different depths
Solution Approach 1:
The support member is designed with a fold line that allows it to be bent to different angles, and the extension member can be folded along score lines to adjust the overall length. This dynamic configuration enables the bracket to adapt to different wall cavity depths while maintaining a relatively simple structural design.
Solution Approach 2:
The bracket's effective length parameter can be changed by folding the extension member along different score lines or by bending the support member at the fold line. This allows the same bracket structure to be configured for various wall depths without requiring multiple different bracket designs.
3Adaptability or versatility
If an extendable support member with fold lines is added to accommodate different wall depths, then adaptability improves, but the bracket structure becomes more complex
Solution Approach 1:
The bracket is segmented into distinct functional portions (body member, support member, extension member) connected by fold lines. This segmentation allows each portion to be simple in design while the combination provides the needed adaptability through folding configurations.
Solution Approach 2:
The bracket utilizes flexible folding joints instead of rigid connections, allowing the thin metal bracket to bend and extend to different configurations. This flexible approach enables adaptability without adding significant structural complexity or requiring additional mechanical components.
Data Source
AI summary
A mounting bracket is provided for supporting an electrical box to a support structure. The mounting bracket includes a mounting base for coupling to the electrical box, and a body member extending perpendicular to the mounting base and extending against the back wall of the electrical box. The body member includes a support member and extension member that can be folded outwardly from the back wall of the electrical box to contact an opposing wall and support the electrical box. In another embodiment, the mounting bracket includes a front plate with a central opening for receiving an electrical box and a pair of extension members that extend in a rearward direction with respect to the electrical box. The support members can include an extension member that can be folded outwardly to contact an opposing wall surface to support the electrical box.