Post-Construction Wall Box Clenching Bracket Design
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Solution Overview
Problem
There is a need for a low-voltage wall enclosure that can be easily installed and reused in residential electrical systems without requiring additional wall construction, particularly in situations where access to a wall stud is not straightforward.
Innovation Solution
A post-construction wall box system comprising a clenching bracket and an enclosure, where the clenching bracket is inserted into a wall opening, compressed to pass through, and then expanded to engage the interior surface, allowing the enclosure to be securely attached using joining screws that engage the exterior and interior flanges with the wall edge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional wall enclosures are mounted to wall studs during construction, then high voltage electrical requirements are met, but additional wall construction is required and installation is complex
Solution Approach 1:
The mounting system is divided into separate components: a wall box unit and a separate clenching bracket. The clenching bracket is inserted into the wall opening and expanded behind the wall board to engage with wall studs or structural elements, while the wall box attaches to the bracket. This segmentation allows the mounting function to be separated from the wall construction itself, enabling post-construction installation without requiring integrated wall stud access.
Solution Approach 2:
The clenching bracket serves as an intermediary component between the wall box and the wall structure. It is inserted through the wall opening and expanded behind the wall board to create a secure mounting surface. This intermediary allows the wall box to be mounted without direct access to wall studs during construction, bridging the gap between the wall surface and the structural elements.
2Adaptability or versatility
If wall enclosures are permanently installed during construction, then structural stability is ensured, but reusability and removability are lost
Solution Approach 1:
The clenching bracket incorporates dynamic expansion and contraction capabilities. It is inserted in a compressed state through the wall opening, then expanded behind the wall board to engage with structural elements. This dynamic behavior allows the bracket to transition from a compact installable state to a stable mounted state, and can be contracted again for removal and reuse, providing both stability during use and adaptability for relocation.
Solution Approach 2:
The mounting system is designed to be recoverable and reusable. The clenching bracket can be removed from the wall structure, and the wall box can be detached and reused in different locations. This contrasts with traditional permanent construction-mounted enclosures, allowing the components to be recovered and reused without damage, enhancing adaptability while maintaining mounting stability during use.
3Productivity
If additional wall construction is performed to accommodate wall boxes, then proper mounting support is provided, but construction time and cost increase
Solution Approach 1:
The clenching bracket is designed to be pre-assembled with the wall box unit before installation. This preliminary assembly allows the complete mounting system to be installed as a single unit through the wall opening, eliminating the need for additional wall construction steps during or after building completion. The pre-assembled unit includes all necessary components for secure mounting, providing both speed and simplicity.
Solution Approach 2:
The mounting function is extracted from the wall construction process itself. Instead of building wall structures to accommodate enclosures, the clenching bracket is inserted through existing wall openings and expanded behind the wall board to provide mounting support. This extraction separates the mounting function from wall construction, allowing installation without additional wall building, thereby increasing productivity while reducing construction complexity.
Data Source
AI summary
A post construction wall mounting box assembly (100) is formed from an enclosure (200) and a clenching bracket (300) which are joined together with joining screws (431, 432) where the enclosure includes a first set of parallel and opposed sidewalls (210) having exterior wall flanges (214) and the clenching bracket includes first and second slideable sidewall portions (310, 320) that have interior wall flanges (314, 324) and these exterior and interior wall flanges cooperate to engage an edge of a wall board when the joining screws are tightened.