Adjustable Electrical Box with Sliding Mounting Mechanism
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Solution Overview
Problem
Conventional electrical boxes are inflexible and difficult to adjust once mounted, as they are typically one-piece structures that cannot be easily moved or repositioned without disassembly, which limits their installation precision and flexibility in various structural contexts.
Innovation Solution
An adjustable electrical box design featuring a mounting screw system with a sliding tab and track mechanism that allows the box to be moved and locked in different positions relative to a stud, enabling horizontal movement and adjustment perpendicular to the stud's axis, while preventing vertical movement to maintain secure engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional one-piece electrical box structure is used, then manufacturing simplicity is maintained, but adjustability and repositioning capability are lost
Solution Approach 1:
The electrical box is divided into multiple segments: a stationary rear portion attached to the stud and a movable front portion containing the device mounting area. The mounting tab and slot mechanism creates distinct movable and fixed sections, allowing the front portion to slide horizontally along the stud while the rear remains anchored.
Solution Approach 2:
The electrical box transitions from a completely static one-piece structure to a dynamic system where the front portion can slide horizontally along the stud. The mounting tab engages with the slot to permit controlled movement in one direction while maintaining connection to the stud, enabling adjustment and repositioning capability.
2Adaptability or versatility
If mounting screw is tightly secured, then structural stability is improved, but adjustability and repositioning capability are reduced
Solution Approach 1:
The mounting mechanism transitions between two states: when the mounting screw is loose, the tab can slide freely in the slot allowing repositioning; when the screw is tightened, the tab is secured at a specific position providing stability. This dynamic state change enables both adjustability and stable mounting.
Solution Approach 2:
The mounting screw controls the engagement parameter between the tab and slot. By adjusting the screw tension, the system transitions between a loose state permitting movement and a tight state providing stable fixation, allowing the installer to choose between repositioning capability and mounting stability as needed.
3Ease of operation
If electrical box is made movable for adjustment, then installation flexibility is improved, but structural stability and secure mounting are compromised
Solution Approach 1:
The mounting tab and slot create a dynamic connection that allows controlled movement during installation while maintaining secure attachment to the stud. The horizontal sliding capability provides installation flexibility, while the vertical constraint and screw fixation ensure mounting security once positioned.
Solution Approach 2:
The mounting tab acts as an intermediary between the electrical box and the stud, providing a controlled interface that permits horizontal adjustment while maintaining secure vertical mounting. The tab mediates between the need for movement and the need for stable attachment.
4Adaptability or versatility
If mounting slot allows horizontal movement, then adjustability perpendicular to stud axis is improved, but vertical stability is reduced
Solution Approach 1:
The mounting slot has different properties in different directions: it permits horizontal movement along the stud axis while preventing vertical movement perpendicular to the stud. This anisotropic design provides horizontal adjustability while maintaining vertical stability through the geometric constraints of the slot orientation.
Data Source
AI summary
An electrical box including at least four sides extending from a bottom to an open top and at least two device securing protrusions each having an aperture adjacent to each of at least two sides, each device securing aperture including an opening extending toward the open top of the electrical box, at least one mounting slot within one of the at least four sides, a mounting screw extending through the at least one mounting slot and adapted to secure the electrical box to a stud, and wherein the mounting screw is manipulated from within the open top and permits movement of the electrical box relative to the stud when the mounting screw is at least partially disengaged.