Rework Bracket Structure for Old-Work Outlet Box Mounting
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Solution Overview
Problem
Conventional electrical outlet boxes designed for 'cut-in' or 'old work' applications in existing walls are difficult to install due to the need for extensive fabrication, complex mounting hardware, and require specific boxes for each application, leading to inefficiencies and compliance issues with standards like UL and CSA.
Innovation Solution
A bracket system with a first end section, middle section, and second end section, featuring bendable members and offset design, allowing for secure mounting of standard electrical outlet boxes without screws or fasteners, facilitating easy installation in existing walls by engaging the box's exterior and providing a spring-like effect for snug fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If swing-out clips are used to secure the box to the wall, then the box can be mounted without stud access, but the clips are difficult to manipulate in tight installation environments and require extensive box modification
Solution Approach 1:
The patent introduces a separate mounting bracket as an intermediary device between the electrical box and the wall. The bracket includes tabs that pass through the wall opening and engage with the box exterior, while opposite tabs engage the back surface of the wall. This intermediary bracket solves the manipulation difficulty by providing a structure that can be installed from the front of the wall opening without requiring tight-space operations behind the wall.
Solution Approach 2:
The mounting system is segmented into distinct functional components: the electrical box, the mounting bracket with front-facing tabs, and the wall structure. The bracket is divided into sections with tabs extending from different faces, allowing independent engagement with the box and the wall. This segmentation enables simplified installation procedures and avoids the need for complex swing-out mechanisms.
2Strength
If clips are mounted on the exterior surface of the side walls, then the box can be secured to the wall, but a larger hole must be cut through the wall requiring extensive wall repair
Solution Approach 1:
The mounting bracket utilizes three-dimensional tab extensions from multiple faces of the bracket body. Tabs extend from the front face to engage the box exterior, while opposite tabs extend from the back face to engage the wall surface. This multi-dimensional tab arrangement provides strong mechanical engagement without requiring an enlarged wall opening, as the tabs utilize the existing opening geometry efficiently.
3Adaptability or versatility
If compression devices, toggle clips, or snaps are used to secure the box, then the box can be mounted without studs, but these structures are difficult for installers to operate
Solution Approach 1:
The mounting bracket is designed with tabs that automatically engage the wall surface and box exterior through simple insertion and pressing motions. The rigid bracket structure with extended tabs allows the installer to secure the box by straightforward front-facing operations, eliminating the need for complex compression devices, toggle clips, or snaps that require difficult manipulation in tight spaces behind the wall.
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
Enables the use of standard electrical boxes in old work applications with simplified installation, reducing fabrication needs and compliance issues, while providing secure and flexible mounting without extensive wall modifications or additional hardware.
Implementation Method 1
The middle section can include a bendable member that extends from the first side of the middle section in substantially the same plane as the middle section and the bendable member can have an aperture
Data Source
AI summary
A bracket for electrical outlet boxes that includes: a first end section, a middle section and a second end section, wherein each section has a substantially planar surface, a first side, a second side, a top surface and a bottom surface, wherein the middle section is offset from and substantially parallel to the first and second end sections; first and second offset portions connecting the middle section to the first and second end sections; first and second opposing ends extending upwardly and substantially perpendicular to the first and second end sections; a first tab and a second tab extending in opposing relation to each other from the first side of the first and second ends; a first leg and a second leg extending downwardly from the second side of the first and second end sections; and a bendable member extending from the first side of the middle section.