Unitary Outlet Box Mounting Plate for Secure Stud Attachment
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Solution Overview
Problem
Conventional outlet box mounting assemblies fail to securely attach to wall studs, leading to unwanted deflection and require multiple components for assembly, which is labor-intensive and does not allow for additional bracket or outlet box mounting on the opposite side of the stud.
Innovation Solution
A single unitary combination mounting plate and cover assembly that serves as a raised cover ring, box support, and secondary bracket/outlet box support, featuring openings for securing the outlet box, holes for stud attachment, and apertures for additional mounting on the opposite side, reducing component count and preventing unwanted movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mounting assemblies use multiple separate components (outlet box support and raised cover ring), then the outlet box can be mounted to the stud, but the assembly process becomes labor intensive and complex
Solution Approach 1:
The patent combines the outlet box support and raised cover ring into a single integrated mounting assembly that includes both functions. The assembly features a box support portion for mounting the outlet box to the stud and a raised cover ring portion that surrounds and covers the outlet box, eliminating the need for separate components and reducing assembly complexity
Solution Approach 2:
The mounting assembly is designed to perform multiple functions simultaneously: it supports the outlet box, secures it to the stud, provides a raised cover ring for safety and aesthetics, and includes a stiffening arm to prevent deflection. This multi-functional design replaces what would traditionally require multiple separate components
2Reliability
If conventional mounting assemblies use separate outlet box support and cover ring components, then the outlet box can be secured to the stud, but assembly requires sequential connection of multiple parts which is labor intensive
Solution Approach 1:
The outlet box support and raised cover ring are merged into a single pre-assembled unit that can be installed in one operation, eliminating the time required to sequentially connect multiple separate components while maintaining secure mounting
3Reliability
If conventional mounting assemblies securely attach to the stud, then the outlet box is firmly mounted, but additional brackets or outlet boxes cannot be mounted on the opposite side of the stud
Solution Approach 1:
The mounting assembly is designed with dual functionality: it securely mounts the primary outlet box to the stud while also providing mounting capability on the opposite side of the stud for additional brackets or outlet boxes, enhancing versatility without compromising secure attachment
4Device complexity
If conventional mounting assemblies are used without stiffening arms, then the assembly is simpler, but undesired deflection occurs in the outlet box when force is applied
Solution Approach 1:
The stiffening arm is integrated into the mounting assembly as a unified component rather than a separate auxiliary part. The stiffening arm extends from the box support portion to provide structural reinforcement that prevents deflection of the outlet box when force is applied, while maintaining overall assembly simplicity
Data Source
AI summary
Combination mounting plate and cover assemblies for mounting an electrical outlet box on one side of a stud in a wall are provided. The mounting plate and cover assemblies are configured to receive an additional bracket and/or outlet box on an opposite side of the stud. The combination mounting plate and cover assemblies can be single unitary members serving the multiple functions of a raised cover ring, a box support, and a secondary bracket/outlet box support. Systems including combination mounting plate and cover assemblies having an electrical box and a bracket or second outlet box attached thereto.