Resilient Clip for Adjustable Junction Box Mounting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for coupling electrical junction boxes to support members are inflexible, especially when pre-wired or pre-assembled, requiring time-consuming adjustments and using large, expensive brackets that consume space and material, limiting mounting options and increasing manufacturing complexity.
Innovation Solution
A clip system with a coupling member and flange that engages support members, allowing for adjustable positioning of electrical junction boxes with a small footprint, using a resilient design that requires minimal material and manufacturing steps, enabling easy assembly and repositioning without disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional brackets are used to couple electrical junction boxes to support members, then the junction boxes can be mounted, but the brackets consume large amounts of space and material, limiting mounting options and increasing manufacturing complexity
Solution Approach 1:
The coupling device is divided into two separate components: a mounting bar with coupling flaps that attaches to structural members, and a clip that couples the electrical junction box to the mounting bar. This segmentation allows each component to be optimized independently, reducing overall complexity while maintaining versatility.
Solution Approach 2:
The clip is designed with resilient properties, allowing it to be compressed and expanded. This dynamic characteristic enables the clip to accommodate different junction box sizes and positions, providing adaptability without requiring multiple fixed-size brackets, thereby reducing manufacturing complexity.
2Productivity
If pre-wired or pre-assembled electrical junction boxes are used, then installation time is reduced, but the ability to adjust position at the job site is lost, requiring time-consuming disassembly and reassembly
Solution Approach 1:
The resilient clip can be compressed to release the electrical junction box from the mounting bar, and expanded to secure it again. This dynamic mechanism allows installers to easily reposition pre-wired or pre-assembled boxes at the job site without complex disassembly procedures, maintaining both installation efficiency and position adjustability.
Solution Approach 2:
The clip's resilient design allows it to be manually compressed and expanded by the installer without requiring tools or complex mechanisms. The clip essentially serves itself by using its own elastic properties to enable easy attachment and detachment, facilitating position adjustments while maintaining productivity.
3Strength
If large brackets are used to couple electrical junction boxes, then secure mounting is achieved, but material usage increases and manufacturing complexity increases
Solution Approach 1:
By separating the mounting function (coupling flaps on mounting bar) from the box-coupling function (clip), each component can be minimized in size while maintaining strength. The clip uses only the material necessary to create a resilient grip, significantly reducing material usage compared to a single large bracket that must accommodate all functions.
Solution Approach 2:
The clip utilizes resilient material properties to create a flexible coupling mechanism that achieves strong mounting without requiring thick or abundant material. The elastic deformation of the clip provides both strength and adaptability, reducing material consumption while maintaining mounting integrity.
Data Source
AI summary
Clips for coupling devices, such as electrical junction boxes, to support members are provided. In one example, a clip for coupling an electrical junction box to a support member includes a coupling member and a flange. The coupling member is adapted to engage the support member and includes a first member, a second member spaced-apart from the first member, and a third member extending between and engaging the first and second members. The first, second and third members together define a receptacle adapted to receive the support member therein. The flange extends from the coupling member and defines a fastener opening therein adapted to receive a fastener for coupling the clip to the electrical junction box.