Multi-Gang Mounting Bracket for Flush Junction Box Installation
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Solution Overview
Problem
Existing mounting solutions for junction boxes lack versatility in accommodating various junction box sizes and wall stud spacings, requiring multiple bracket lengths and sizes, which complicates installation and compliance with electrical codes.
Innovation Solution
A multi-gang junction box mounting bracket with a face plate, stud mounting flange, and box mounting flange that attaches to wall studs and engages the junction box, allowing for secure mounting of multiple device types across different sizes and spacings, ensuring flush surfaces for code compliance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple bracket lengths and sizes are used to accommodate various junction box sizes and wall stud spacings, then adaptability is improved, but device complexity increases
Solution Approach 1:
The mounting bracket is designed with a universal configuration that can accommodate multiple junction box sizes (single-gang, double-gang, triple-gang, quadruple-gang) and various wall stud spacings using the same bracket design. The bracket includes a face plate with multiple flange configurations that can be selectively positioned to match different installation requirements, eliminating the need for multiple specialized bracket sizes.
Solution Approach 2:
The mounting bracket is divided into distinct functional segments: a face plate, multiple flange configurations (stud mounting flange, box mounting flange, center mounting flange), and fastening elements. These segments can be selectively positioned and configured depending on the specific installation requirements, allowing a single bracket design to adapt to various junction box sizes and stud spacings.
2Device complexity
If a single bracket size is used for various junction box sizes and spacings, then device complexity is reduced, but adaptability worsens
Solution Approach 1:
The mounting bracket incorporates dynamic configurability through multiple flange configurations that can be selectively positioned along the face plate. The flanges can be moved to different locations and orientations to adapt to various junction box sizes and wall stud spacings, transforming a static bracket into a dynamically adaptable mounting solution.
Solution Approach 2:
The bracket design allows for parameter changes in flange positioning, orientation, and configuration to accommodate different installation scenarios. By changing the position and configuration of the flanges rather than changing the entire bracket, the system achieves adaptability while maintaining a single bracket design.
3Ease of operation
If traditional mounting brackets are used, then installation is simple, but compliance with electrical codes deteriorates due to gaps between bracket and cover plate
Solution Approach 1:
The invention replaces traditional mechanical mounting methods that leave gaps with a flush-mounted system where the face plate and flanges create a continuous surface. The box mounting flange engages the side wall of the junction box to pull it flush against the face plate, eliminating gaps without complicating the installation process.
Data Source
AI summary
A mounting bracket attaches a junction box to a wall stud. The mounting bracket includes a face plate, stud mounting flange, and box mounting flange. The face plate has opposite upper and lower and opposite left and right edge margins. The stud mounting flange extends laterally from the left edge margin of the face plate. The box mounting flange is attached to the right edge margin of the face plate. A method of coupling a mounting bracket and junction box includes engaging a side wall of the junction box with a box mounting flange of the mounting bracket. A front surface of a face plate of the mounting bracket is flush with a front surface of the junction box. A stud mounting flange of the mounting bracket extends laterally from the side wall of the junction box and connects to a side end margin of the face plate.