Recessed Outlet Box Bracket System for Floor Fire-Stop Sealing
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Solution Overview
Problem
In-floor fittings with tall profiles can extend below the concrete floor surface, causing intumescent material to expand downward and lose effectiveness as a fire-stop seal, and existing designs often have uneven surfaces or protrusions that complicate cable management and aesthetics.
Innovation Solution
A recessed outlet box system with a bracket system that includes an insert body, cover, and retention brackets, where the insert body is secured within a hole in the floor using barbs and legs that direct the intumescent material's expansion inward, maintaining the seal and allowing cables to pass through a flush or slightly elevated cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a tall profile in-floor fitting is used to accommodate plugs and receptacles, then the fitting can receive plugs completely inside the body, but the fitting extends below the floor surface and causes intumescent material to expand downward losing fire-stop effectiveness
Solution Approach 1:
The patent redirects the expansion direction of intumescent material from vertical (downward) to horizontal (inward toward center) by changing the dimensional constraints. The angled legs and barbs create a geometric structure that channels expansion forces laterally, preventing downward expansion while maintaining fire-stop integrity.
Solution Approach 2:
The intumescent material is positioned in advance between the angled legs and barbs, ready to expand into the constrained space when activated by heat. The pre-positioned material and pre-formed geometric constraints ensure that when expansion occurs, it automatically follows the intended inward path rather than downward.
2Ease of operation
If a tall profile fitting is used, then plugs can be received inside the body, but the fitting extends below the shallowest points of convoluted floor structures
Solution Approach 1:
The patent transitions from a vertical profile solution to a horizontal constraint solution. By using angled legs that spread outward and barbs that engage the floor walls laterally, the fitting achieves its functional height without extending below the floor surface, solving the alignment issue with convoluted floor structures.
3Quantity of substance
If intumescent material is allowed to expand downward without boundaries, then the material can fill the space, but the material separates from the fitting and diminishes fire-stop effectiveness
Solution Approach 1:
The patent creates different spatial zones with different properties: the space between the angled legs and barbs is designed to receive and contain the intumescent material, while the outward-facing sides of the legs are left open for structural engagement with the floor. This local differentiation ensures material retention where needed while maintaining structural integrity.
4Ease of operation
If covers extend above the floor surface or include uneven surfaces, then cable egress is enabled, but cable management becomes complicated and aesthetics are compromised
Solution Approach 1:
The patent moves the cable egress function from the vertical dimension (covers extending above surface) to the horizontal dimension (flush covers with integrated cable management). The angled legs and barbs create horizontal engagement with the floor structure, allowing the cover to remain flush while cables pass through designated openings.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively seals against heat and moisture while allowing cables to be routed beneath the floor surface without protrusions, enhancing the fire-stop performance and aesthetic appeal by maintaining a flush or slightly elevated profile.
Implementation Method 1
the barbs of the first and second brackets extend to resistably engage the wall of the hole to retain the insert body in the hole
Implementation Method 2
intumescent material that expands when activated by a source of heat, such as a fire below the floor. The expansion of the intumescent material effectively forms a seal within the fitting to prevent heat penetration
Implementation Method 3
physically and thermally sealing the outlet box
Implementation Method 4
seals against heat and moisture
Data Source
AI summary
A bracket system for retaining an outlet box in a hole in a floor. The bracket system includes an insert body configured to be positioned in the hole in the floor, a cover configured to cover the insert body, and at least first and second brackets. Each bracket includes a base plate configured to be mounted in the insert body. The base plate includes at least one leg extending therefrom and at least one barb extending therefrom. The insert body includes holes in an exterior wall thereof through which the barbs of the first and second brackets extend to resistably engage the wall of the hole to retain the insert body in the hole and the legs of the first and second brackets are secured to the cover.