Universal Mounting Bracket for Electrical Junction Boxes
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Solution Overview
Problem
The complexity of conventional metal electrical junction boxes and their mounting systems leads to increased inventory needs and costs for manufacturers and retailers, due to the variety of box sizes and shapes, resulting in burdensome inventory management and installation challenges.
Innovation Solution
Modular brackets and knockouts designed to be universally compatible with different sized and shaped electrical junction boxes, using a standardized distance between mounting holes and customizable knockout configurations, allowing for versatile installation and reduced inventory requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional metal electrical junction boxes with various brackets and mounting means are used, then different box sizes and shapes can be accommodated, but inventory space requirements and SKU tracking complexity increase significantly
Solution Approach 1:
The mounting bracket is designed with a universal configuration that can accommodate multiple box sizes and shapes through adjustable mounting ear positions and interchangeable mounting means, eliminating the need for separate brackets for each box type
2Adaptability or versatility
If multiple different brackets and mounting means are provided for various junction box types, then all box configurations can be mounted, but the number of SKUs and inventory tracking burden increase
Solution Approach 1:
A single universal bracket design with interchangeable mounting means and adjustable mounting ear positions replaces multiple specialized brackets, reducing the inventory of unique items while maintaining the ability to mount various box types
Solution Approach 2:
The mounting system is divided into separate interchangeable components (mounting means and mounting ears) that can be mixed and matched, allowing a single bracket body to serve multiple functions across different box configurations
3Adaptability or versatility
If conventional mounting systems with multiple bracket types are used, then different junction box configurations can be installed, but installation time and complexity increase
Solution Approach 1:
The universal bracket with pre-positioned mounting ears and interchangeable mounting means allows installers to work with a single bracket type across all box configurations, reducing installation time by eliminating the need to select and handle multiple specialized bracket types
Data Source
AI summary
Electrical accessories and associated methods of use and manufacture are shown and described. In one example embodiment, a system includes a plurality of electrical junction boxes. Each electrical junction box includes at least one wall with a pair of spaced-apart holes, wherein the holes are sized and shaped to receive a pair of corresponding mounting devices. The system also includes at least one mounting bracket. The mounting bracket includes a pair of spaced-apart mounting devices, wherein the mounting devices are sized and shaped to protrude through the pair of corresponding spaced-apart holes in the plurality of electrical junction boxes. At least one of the plurality of electrical junction boxes is maintained in a relative stationary position with respect to the at least one bracket when the pair of spaced-apart mounting devices protrudes through the respective pair of spaced-apart holes in the wall of the at least one electrical junction box.