Adjustable Electrical Box Cover Plate for Varying Wall Thicknesses

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Solution Overview

Problem

Existing electrical box mounting solutions often fail to accommodate varying wall thicknesses, leading to recessed electrical devices that are inaccessible and difficult to position correctly, especially in new or renovated constructions.

Innovation Solution

An adjustable electrical box cover plate with a telescoping member and sliding sleeve system that allows for axial adjustment within a collar, enabling the electrical device to be positioned flush with the wall surface, accommodating different wall thicknesses and ensuring easy access.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a fixed electrical box mounting plate is used, then the structure is simple and easy to manufacture, but it cannot accommodate varying wall thicknesses resulting in recessed electrical devices

Engineering Contradiction:

Improveaccommodation of varying wall thicknessesVSAvoidmounting plate structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The mounting plate incorporates a telescoping member with a sliding sleeve that can move axially between retracted and extended positions. This dynamic structure allows the electrical device to be positioned at the desired distance from the wall surface by adjusting the sleeve position, thereby accommodating varying wall thicknesses while maintaining a relatively simple overall structure.

Inventive Principle:

Principle #15Dynamics

2Ease of operation

If the electrical box is recessed in the wall, then the wall structure integrity is maintained, but the electrical device becomes inaccessible and difficult to position

Engineering Contradiction:

Improveelectrical device accessibilityVSAvoidelectrical device position relative to wall surface

Core Design Contradiction:

Ease of operationVSShape

Solution Approach 1:

The sliding sleeve can be extended to protrude through the wall surface, bringing the electrical device to an accessible position. The telescoping mechanism allows the device to be positioned flush with or protruding from the wall surface while maintaining proper installation depth, thereby improving accessibility without compromising wall structure.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If adjustment mechanisms are added to accommodate wall thickness variations, then adaptability improves, but the manufacturing complexity and cost increase

Engineering Contradiction:

Improveadjustment to different wall thicknessesVSAvoidmounting plate production

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The telescoping member with sliding sleeve provides a simple yet effective adjustment mechanism. The sleeve slides within the collar along the mounting plate's central axis, allowing easy adjustment of the electrical device position. This design achieves adaptability through a straightforward mechanical structure that is relatively easy to manufacture and assemble.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS7531743B2Electrical box mounting plate with adjustable ring

Publication Date: 2009.05.12 HUBBELL INC

AI summary

An electrical box assembly includes an adjustable electrical box cover. The cover includes a base having a central opening and a collar encircling the central opening. A sleeve slides through the collar and is adjusted by a plurality of adjustment screws. In one embodiment, the adjustment screws are positioned within the sleeve and the collar. The sleeve and collar have inwardly extending tabs to receive the adjustment screws allow adjustment of the sleeve with respect to the collar.