Self-Supporting Wall Frame for Retrofit Electrical Boxes
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Solution Overview
Problem
Retrofitting existing building walls to install electrical or low-voltage devices requires skilled labor and is labor-intensive due to the need for secure attachment without pre-existing wall studs, as existing methods lack ease and speed in creating new openings and attachments.
Innovation Solution
A self-supporting frame apparatus with adjustable flanges and mounting arrangements that fits within pre-existing wall openings, allowing for secure attachment and easy installation of electrical boxes or low-voltage devices, featuring various flange configurations such as leaf springs, coil springs, and pivot arms to ensure stability and adjustability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional methods are used to attach electrical boxes to existing wall substrates without pre-existing studs, then secure attachment can be achieved, but the installation becomes labor-intensive and time-consuming
Solution Approach 1:
The frame is pre-assembled with flanges and mounting portions before insertion into the wall opening. The flanges are pre-positioned to engage with the wall substrate, and the mounting portions are ready to receive electrical boxes. This preliminary preparation eliminates the need for on-site assembly and significantly reduces installation time while maintaining secure attachment.
Solution Approach 2:
The frame acts as an intermediary device between the wall substrate and the electrical box. It provides a standardized interface that simplifies the attachment process: the flanges engage with the wall substrate to provide support, while the mounting portions securely hold the electrical box. This intermediary structure transforms a complex direct attachment problem into two simpler engagement interfaces.
2Reliability
If skilled labor is used for retrofitting applications requiring addition of electrical or low voltage device access to pre-existing building walls, then proper installation can be achieved, but labor costs and complexity increase
Solution Approach 1:
The frame is designed to be self-aligning and self-supporting within the wall opening. The flanges automatically engage with the wall substrate upon insertion, and the mounting portions are pre-configured to receive electrical boxes without requiring complex alignment or additional fastening operations. This self-service design reduces the skill level required for installation while ensuring proper installation quality.
3Ease of manufacture
If a fixed frame design is used for wall openings, then manufacturing is simplified, but adaptability to different wall thicknesses and opening sizes is reduced
Solution Approach 1:
The frame incorporates adjustable elements such as slidable flanges or expandable sections that can be modified after manufacturing to match different wall thicknesses and opening sizes. The frame may include telescoping members or adjustable bracing that allow it to adapt to various dimensions while maintaining structural integrity. This dynamic capability enables a single standardized frame design to serve multiple installation scenarios.
Solution Approach 2:
The frame design allows for parameter adjustments such as flange length, frame width, and depth to accommodate different wall substrates. These parameters can be modified through simple mechanical adjustments or by selecting from a limited family of standardized sizes, balancing manufacturing simplicity with field adaptability.
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
Facilitates quick and easy installation of electrical or low-voltage devices in existing walls by providing a secure, adjustable frame that fits various wall substrates, reducing labor intensity and allowing for flexible placement and size adjustments.
Implementation Method 1
a flange may be comprised of a leaf spring that is biased for contact with the inner wall surface
Implementation Method 2
The spring may be held to clear the wall opening when the frame is inserted and then released thereafter
Implementation Method 3
A coil spring may be used as a spring loaded retainer biased for contact with the inner wall surface
Implementation Method 4
The protruding elements and the frame may comprise electrically conductive material, the frame thereby being grounded to the electrical boxes
Data Source
AI summary
A self-supporting apparatus can be placed in a pre-set opening in an existing wall substrate. A frame assembly is configured with a perimeter that corresponds to the thickness of the wall substrate. The edge of the frame thus can be in fitting contact with the substrate opening. Flanges on opposite sides of the frame extend in the planar direction of the wall substrate to be in contact with the inner and outer surfaces of the substrate to maintain the frame in position in the wall and to strengthen the structure. The frame can include appropriate mounting portions for mounting electrical boxes or low voltage devices within the wall.