Plastic Adjustable Electric Box Bracket with Interlocking Ribs

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Solution Overview

Problem

Current adjustable electric box and bracket combinations made of metal are heavy and costly for shipping, and they can rust, whereas plastic alternatives are lighter and more cost-effective but lack stability and insulation.

Innovation Solution

The use of a plastic adjustable electric box and bracket assembly with interlocking ribs and grooves for secure fit and stability, and the incorporation of gussets for added strength, allowing for depth adjustment without volume loss and providing electrical insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal brackets are used for adjustable electric box combinations, then strength and stability are improved, but weight and shipping cost increase significantly

Engineering Contradiction:

Improvebracket strengthVSAvoidcombination weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent uses plastic material for the bracket instead of metal, achieving a composite solution that provides sufficient strength while dramatically reducing weight. The plastic bracket incorporates structural features like gussets and interlocking mechanisms to compensate for the lower inherent strength of plastic compared to metal.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The bracket is divided into multiple components including arms, gussets, and interlocking features that work together to provide strength. This segmentation allows each part to be optimized for its specific function while using lighter plastic material throughout the assembly.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If metal brackets are used for adjustable electric box combinations, then structural stability is improved, but rusting occurs

Engineering Contradiction:

Improvestructural stabilityVSAvoidrust

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The patent employs plastic material that inherently resists rust and corrosion, eliminating the harmful effect of rusting while maintaining structural stability through carefully designed geometric features and interlocking mechanisms.

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If adjustment depth is increased using metal brackets, then stability is improved, but internal volume of the box is reduced

Engineering Contradiction:

Improveadjustment stabilityVSAvoidbox internal volume

Core Design Contradiction:

Stability of the object's compositionVSVolume of moving object

Solution Approach 1:

The adjustment mechanism is segmented into modular components including the bracket arms, gussets, and interlocking features that allow depth adjustment without requiring intrusive metal structures that would encroach on the box's internal volume.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11532927B2Adjustable electric box and bracket combination

Publication Date: 2022.12.20 CANTEX INC

AI summary

Electric boxes and hanging brackets and more particularly adjustable electric boxes with parallel rails for connection with reciprocal parallel grooves in a hanging bracket that is configured to connect to a support, for example, a wall stud.