Adjustable Floor Box With Rotating Mount Plate and Universal Conduit Fit
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Solution Overview
Problem
Existing floor boxes lack the ability to adjust the orientation of electrical components after concrete pouring and accommodate conduit diameter changes without using additional couplers.
Innovation Solution
A floor box assembly with a mounting plate and adapter ring that allows 360-degree rotation of electrical components and accommodates various conduit diameters without reducers or enlargers, using fasteners and serrations for secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional adapter rings with capturing features are used to adjust electrical component orientation, then the electrical component can be oriented relative to the floor box, but the ability of the installer to orient the electrical components is limited and subsequent serviceability is restricted due to adhesive bonding
Solution Approach 1:
The mounting plate incorporates a rotating mechanism with a serrated interface that enables dynamic adjustment of the electrical component orientation. The rotating member can be freely positioned to any angle and then locked in place, providing both flexibility during installation and serviceability later. This dynamic adjustment capability resolves the contradiction by allowing full orientational freedom without the limitations of conventional capturing features.
Solution Approach 2:
The adapter ring is segmented into a floor box interface portion and a mounting plate interface portion with a rotating mechanism between them. This segmentation allows the mounting plate to rotate independently relative to the floor box, enabling the electrical component to be oriented at any angle while maintaining a secure connection. The segmentation resolves the contradiction by decoupling the fixed floor box mounting from the adjustable component mounting.
2Adaptability or versatility
If reducers or enlargers are used to couple conduits of different diameters to the floor box inlet/outlet, then various conduit diameters can be accommodated, but additional components and gluing processes are required
Solution Approach 1:
The floor box inlet/outlet is designed with a universal receiving structure that can accommodate conduits of various diameters directly. The adapter ring incorporates a conduit receiving portion with a enlarged opening that can accept different conduit sizes without requiring additional reducers or enlargers. This multi-functional design resolves the contradiction by providing conduit diameter adaptability while eliminating the need for extra components.
Solution Approach 2:
The adapter ring merges the functions of the floor box inlet/outlet and the conduit coupling into a single integrated component. The adapter ring's conduit receiving portion combines the inlet/outlet function with the ability to directly receive various conduit diameters, eliminating the need for separate reducers or enlargers. This merging resolves the contradiction by reducing device complexity while maintaining adaptability.
3Stability of the object's composition
If the floor box is installed before concrete pouring, then the floor box can be positioned within the concrete floor, but the orientation cannot be adjusted after the concrete has been poured
Solution Approach 1:
The mounting plate incorporates a rotating mechanism that enables dynamic adjustment of the electrical component orientation after the floor box is installed in the concrete. The rotating member can be freely positioned to any angle and then locked, providing post-installation adjustability without compromising the stability of the floor box positioning. This resolves the contradiction by adding orientational flexibility while maintaining installation stability.
4Stability of the object's composition
If adhesive is used to secure the adapter ring to the floor box, then the adapter ring is fixed in position, but subsequent serviceability and adjustability are limited
Solution Approach 1:
The mounting plate uses a mechanical rotating and locking mechanism instead of adhesive bonding to secure the electrical component. This mechanical connection allows the component to be freely adjusted to any orientation during installation and then firmly locked in place. For serviceability, the locking mechanism can be released to allow repositioning. This resolves the contradiction by providing both stable fixation and ease of serviceability through a reversible mechanical connection.
Solution Approach 2:
The mounting plate incorporates a self-locking mechanism that automatically secures the electrical component in the desired orientation without requiring adhesive. The rotating member can be manually positioned and then locked by the self-service mechanism, eliminating the need for external bonding agents. This self-service approach resolves the contradiction by providing stable fixation that remains serviceable through manual operation.
Data Source
AI summary
An electrical floor box system is disclosed. The floor box is arranged and configured to enable an electrical component (e.g., outlet, switch, etc.) received therein to be positioned in any desired orientation so that the orientation of the electrical component can be adjusted as desired. In one embodiment, the electrical component is arranged and configured to be coupled to a mounting plate, which is arranged and configured to be seated within the floor box. In use, the mounting plate is freely adjustable (e.g., 360 degrees of adjustability) relative to the floor box. Once the electrical component has been properly positioned, the mounting plate may be secured to the floor box to secure a position of the mounting plate, and hence the electrical component. In addition, and/or alternatively, in one embodiment, the floor box is arranged and configured to receive various diameter conduits without the need for reducers, enlargers, etc.