Z-Bracket Mounting for Electrical Boxes on Open Metal Studs

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Solution Overview

Problem

Existing methods for mounting electrical boxes to the open face of metal studs are inefficient due to the structural challenges posed by the open shape of metal studs, making it harder to secure accessories compared to the flat side.

Innovation Solution

A Z-shaped mounting bracket with mounting platforms, a retaining tab, and a connecting tab, designed to fit the open face of a metal stud, providing a secure attachment point using grooves and self-tapping screws, and optionally reinforced with triangular braces for stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a mounting bracket is designed to attach to the open side of a metal stud, then it enables mounting electrical boxes to the open face, but the structural stability is reduced compared to mounting on the flat side

Engineering Contradiction:

Improvemounting capability to open faceVSAvoidstructural stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The bracket extends into the open space of the stud by utilizing the depth dimension, with mounting platforms that protrude from the connecting tab to engage with the open face, transforming a 2D surface mounting problem into a 3D spatial engagement solution

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The bracket is formed from a single piece of material (metal or plastic) creating a composite structural unit where the connecting tab, mounting platforms, and reinforcing elements work together as an integrated system to provide both adaptability and stability

Inventive Principle:

Principle #40Composite materials

2Productivity

If a Z-shaped bracket with mounting platforms is used to secure electrical boxes, then mounting efficiency is improved, but the device complexity increases

Engineering Contradiction:

Improvemounting efficiencyVSAvoidbracket structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The bracket is segmented into distinct functional zones: the connecting tab for stud attachment, the mounting platforms for electrical box securement, and triangular braces for reinforcement, allowing each segment to perform its specific function optimally

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bracket is pre-formed with integrated features including pre-positioned mounting holes, pre-formed triangular braces, and pre-configured geometry that matches the open face of metal studs, eliminating the need for on-site fabrication or complex assembly

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11901717B2Bracket for mounting an electrical box to the open face of a metal stud

Publication Date: 2024.02.13 STANLEY E ARNOLD CORP

AI summary

A Z-bracket is adapted for mounting an electrical box to the open face of a metal stud. The invention has two mounting platforms with self-tapping screw holes. The flat brackets of an electrical box are secured to these mounting platforms. The invention has a retaining tab with at least one retaining indentation for screwing the retaining tab to the open face of a metal stud. A connector connects the retaining tab to the mounting platforms. The front edge of each mounting platform has a groove, which accommodates the tongue on a tab of the metal stud. Multiple triangular braces connect the mounting platforms to the connector for structural support. The invention is sized to fit a standard metal stud, providing an improved method for attaching electrical boxes to the open face of a metal stud.