Telescopic Mounting Bracket for Stable Electrical Box Fastening
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Solution Overview
Problem
Existing electrical mounting systems struggle to securely attach electrical components to structural supports, often resulting in loose connections due to inadequate thread engagement and stability.
Innovation Solution
The proposed electrical assembly features a mounting bracket with telescopic support rails and recessed channels, along with centering tabs to maintain alignment and secure the electrical box by deforming its rear wall into the recessed channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical components are attached to structural supports using conventional mounting systems, then installation is simple, but the connection stability is insufficient due to inadequate thread engagement
Solution Approach 1:
The mounting bracket employs nested support rails where an adjustable support rail is inserted into a fixed support rail. This nesting arrangement allows the bracket to adapt to varying structural support configurations while maintaining a compact form factor, resolving the contradiction between connection reliability and device complexity
Solution Approach 2:
The adjustable support rail can slide within the fixed support rail and be secured at different positions using set screws. This dynamic adjustability enables the mounting bracket to accommodate different installation requirements and achieve stable thread engagement, improving connection reliability without excessive complexity
2Reliability
If the electrical box is secured using conventional flat mounting surfaces, then the mounting process is simple, but rotation and loose connections occur due to insufficient locking force
Solution Approach 1:
The mounting bracket introduces recessed channels with locking features at specific locations on the mounting surface. These localized structural features provide enhanced anti-rotation capability and secure locking force precisely where needed, rather than requiring complex modifications to the entire mounting surface
Solution Approach 2:
The recessed channels act as intermediary structures between the electrical box and the mounting bracket. These channels receive and deform the rear wall of the electrical box to create a locking mechanism, providing anti-rotation stability while maintaining ease of installation through a straightforward deformation process
3Adaptability or versatility
If support rails are fixed in position, then manufacturing is simple, but adaptability to different structural support distances is limited
Solution Approach 1:
The support rail system is designed with one fixed rail and one adjustable rail that can slide along the fixed rail. This dynamic configuration allows the bracket to adapt to different structural support distances while maintaining manufacturing simplicity through a modular design that requires only basic machining operations
Solution Approach 2:
The mounting bracket is divided into distinct segments: a fixed support rail, an adjustable support rail, and connection elements. This segmentation allows each component to be manufactured separately using simple processes, then assembled to provide the required adaptability to different installation scenarios
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
This solution provides improved stability and securement of electrical components by allowing full thread engagement and inducing a locking force through deformation, resisting rotation and ensuring a stable electrical connection.
Implementation Method 1
The electrical box may be secured at the front side of the first support rail with the rear wall of the electrical box deformed into the first and second recessed channels
Implementation Method 2
At least one of the centering tabs may extend from the first rail guide to bear against the third rail guide and at least one of the centering tabs may extend from the second rail guide to bear against the fourth rail guide to bias the first and second support rails toward (e.g., to) a centered orientation
Implementation Method 3
a fastener that extends through an aligned set of the first and second support rail mounting holes to secure the electrical box to the mounting bracket
Data Source
AI summary
An electrical assembly for coupling to adjacent structural supports can include a mounting bracket with support rails. The support rails can include a first support rail and a second support rail slidably received within the first support rail. The first support rail can include a first rail guide, a second rail guide, and a first recessed channel extending into a front side between the rail guides. The second support rail can include a third rail guide nested within the first rail guide, a fourth rail guide nested within the second rail guide, and a second recessed channel extending into a front side between the third and fourth rail guides, with the first recessed channel nested within the second recessed channel. An electrical box can include a rear wall secured to the first support rail, such that the rear wall is deformed into the first and second recessed channels.