Support Member for Flush-Mounted Electrical Box
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Solution Overview
Problem
Existing support structures for electrical installation boxes lack the necessary backside support to withstand push and pull forces, are not modular with existing support parts, and complicate flush mounting, especially in multi-board conditions, with no quick installation solution available.
Innovation Solution
A support member with a rear surface removably attached to the electrical installation box, a front surface fixedly attached to the wallboard, and a central cavity with matching profile, featuring fixing members, guiding members, and a split nut assembly for adjustable level support, allowing flush mounting and beam-fixing capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the installation box is mounted flush with the board surface using existing spacers, then the aesthetic appearance is improved, but the structure cannot withstand push and pull forces from sockets and switches
Solution Approach 1:
The support member is divided into distinct functional segments: a front surface for board attachment, a rear surface for box attachment, and a central cavity for receiving existing spacers. This segmentation allows each part to specialize in its function - the front surface provides mounting stability, the rear surface connects to the box, and the central cavity accommodates existing spacer assemblies, thereby achieving both flush mounting and force resistance simultaneously
Solution Approach 2:
The support member acts as an intermediary component between the installation box and the board. It mediates the connection by providing a robust mounting interface on the board side while connecting to the box on the other side, thereby transferring and distributing forces effectively without compromising the flush appearance
2Shape
If existing installation boxes are reused with flush mounting, then aesthetic appearance is improved, but the installation system becomes non-modular and difficult to adapt to multi-board conditions
Solution Approach 1:
The support member is designed with universal adaptability to work with various existing spacer assemblies and installation box types. The central cavity is configured to receive different spacer configurations, and the fixing members can accommodate various mounting scenarios including single-board and multi-board conditions, thereby providing a universal solution that maintains flush mounting while enabling modularity
Solution Approach 2:
The support member incorporates adjustable and configurable features that allow it to adapt dynamically to different installation scenarios. The fixing members can be positioned or configured to suit various board arrangements, and the central cavity can accommodate different spacer heights and types, making the system flexible and adaptable rather than rigid and fixed
3Shape
If larger drill holes are made to accommodate flush mounting, then the installation box can be mounted, but the current installation boxes cannot withstand the pull out forces
Solution Approach 1:
The support member segments the mounting function from the box structure itself. By providing a dedicated mounting interface on the board side with multiple fixing members distributed across the front surface, the pull-out forces are distributed across multiple attachment points rather than concentrated at a single location, thereby withstanding forces that would exceed the capacity of existing box designs
4Shape
If cutters are used to make square holes in the wall for flush mounting, then the installation box can be mounted, but the process is difficult and time-consuming
Solution Approach 1:
The support member replaces the need for complex mechanical cutting operations by providing a pre-configured mounting interface that attaches to the board using standard drilling and fastening operations. Instead of requiring difficult square hole cutting and filling operations, the support member enables straightforward attachment through its fixing members, dramatically reducing installation time and complexity
Data Source
Figure 1
Figure 2(a)~3(b)
Figure 4
AI summary
The present invention relates to a support member (100) for an electrical installation box (10) for flush mounting on a wallboard (14) comprising rear surface (114) removably attached with the electrical installation box, front surface (116) to be fixedly attached with the wallboard, and central cavity (118) of matching profile with entry portion (42) of the electrical box. The rear surface comprises at least a set of fixing member (102-1,102-2) to removably attach with the electrical box, at least a set of guiding members (104) for aligning said fixing members with said electrical box, and at least a receiving provision for receiving split nut assembly (110). The front surface comprises at least a set of releasing slots (118-1, 118-2) and at least a fastener aligning slot (106) disposed opposite to every fixing member and receiving provisions (120) for receiving split nut assembly (110) of said rear surface respectively.