Adjustable Electrical Box for Brick Wall Mounting

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional electrical boxes struggle to be securely anchored, leveled, and aesthetically installed on brick or stone walls, as they rely on cement for mounting, which is difficult to level and visually unappealing, and lack adjustability for flush or offset configurations.

Innovation Solution

An adjustable electrical box assembly featuring a base member with outward tabs and anchoring members that allow for secure fastening to the wall substrate, enabling easy leveling and adjustment for flush or offset mounting, with a design that incorporates a base member and anchoring members to facilitate secure anchoring and mortar adherence.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If conventional electrical box is mounted with cement on brick or stone wall, then the box can be secured to the wall, but it is difficult to level the box with respect to the outer surface of the brick wall

Engineering Contradiction:

Improvesecuring the box to the wallVSAvoidleveling the box

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The mounting system is divided into separate components: an electrical box, anchoring members with adjustable legs, and fasteners. This segmentation allows the box to be secured to the wall while independently adjusting the positioning elements to achieve proper leveling, resolving the contradiction between secure mounting and ease of leveling.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The anchoring members incorporate adjustable legs that can be extended or retracted to different lengths. This dynamic adjustment capability enables the box to be leveled relative to the brick wall surface while maintaining secure anchoring, as the legs can be individually adjusted to compensate for wall irregularities.

Inventive Principle:

Principle #15Dynamics

2Ease of manufacture

If conventional electrical box is mounted flush with the wall substrate, then the installation is simple, but the utility and accessibility to electrical fixtures is reduced

Engineering Contradiction:

Improvesimplicity of installationVSAvoidaccessibility to electrical fixtures

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The adjustable leg mechanism on the anchoring members enables dynamic positioning of the electrical box at either flush or offset configurations. This resolves the contradiction by allowing the box to be mounted flush for simple installation when desired, or extended outward to offset positions for improved accessibility and utility.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The position of the electrical box relative to the wall surface is changed as a variable parameter. The anchoring members allow the box to be positioned at different distances from the wall (flush or offset), enabling optimization between installation simplicity and fixture accessibility based on specific application requirements.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If conventional electrical box has smooth outer sidewalls, then the box is simple in design, but there is no structure for holding the electrical box fast within the mortar

Engineering Contradiction:

Improvesimplicity of box designVSAvoidanchoring strength

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The anchoring members are positioned at specific locations around the electrical box, providing localized anchoring points within the mortar. This resolves the contradiction by maintaining smooth sidewalls on the box itself while introducing anchoring structures at specific locations where they are needed for secure mounting within the mortar.

Inventive Principle:

Principle #3Local quality

4Stability of the object's composition

If cement is used to secure the conventional box, then the box can be mounted on the wall, but the cement around the periphery is visible and detracts from attractiveness

Engineering Contradiction:

Improvesecuring the box to the wallVSAvoidaesthetic appearance

Core Design Contradiction:

Stability of the object's compositionVSShape

Solution Approach 1:

The anchoring function is extracted from the cement mortar and transferred to dedicated anchoring members with fasteners. This allows the cement to be used only for filling gaps and providing a finished appearance, while the actual securing is performed by the anchoring members, eliminating the aesthetic problem of visible cement around the periphery.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS7582827B1Adjustable electrical box for flush or offset mounting of electrical devices on brick or stone walls

Publication Date: 2009.09.01 ARLINGTON IND INC

AI summary

An adjustable electrical box assembly for providing electrical service on a brick or stone wall. The assembly includes a base member, anchoring members, and an electrical box. The base member includes sidewalls with a plurality of outward extending tabs and a top wall with a forward extending lip. The anchoring members are substantially L-shaped with a first leg for anchoring against the substrate of a structure and a second leg for securing to the sidewalls of the base member. The electrical box assembly enables easy mounting and leveling of an electrical fixture either flush with or at some predetermined offset from a brick or stone wall.