Adjustable Junction Box with Removable Cover for Flush Mounting
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Solution Overview
Problem
The installation of electrical junction boxes in buildings is hindered by issues such as drywall mud compromising wires, misalignment with building surfaces, and the need for multiple inspections, leading to increased installation time and complexity.
Innovation Solution
A junction box with a removable cover that allows for adjustable mounting to a wall stud, facilitating one-step installation and inspection, and featuring mechanisms like worm screws or deflectable tabs for easy adjustment and removal, reducing installation time and improving inspection accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the junction box is fixed to the wall stud during rough-in, then the electrical connections can be made, but the junction box cannot be adjusted for alignment with the finished building surface
Solution Approach 1:
The junction box incorporates a dynamic adjustment mechanism that allows it to transition from a fixed state during rough-in to an adjustable state during finish work. The adjustment mechanism includes threads and slots that enable the junction box to move along the wall stud, allowing alignment adjustments after the building surface is completed.
2Ease of operation
If the electrical device is interconnected to the junction box with bosses, then the device can be secured, but the bosses can be filled with drywall mud making it difficult to later interconnect the device
Solution Approach 1:
The invention extracts the electrical device interconnection function from the traditional boss structure. Instead of relying on bosses that can be filled with mud, the electrical device is interconnected to the junction box through the removable cover assembly, which maintains access to connection points while preventing mud contamination.
Solution Approach 2:
The removable cover acts as an intermediary between the electrical device and the junction box interior. It provides a protected interface for electrical connections while preventing drywall mud from reaching the connection points and bosses.
3Productivity
If the junction box is installed early in the process, then electrical connections can be made at rough-in, but the edge of the junction box may not be flush with the internal building surface making it difficult to install finish plates
Solution Approach 1:
The junction box uses a dynamic positioning system with threads and slots that allow it to be moved along the wall stud. This enables the box to be initially installed early for rough-in work, then adjusted later to achieve flush alignment with the finished building surface before finish plate installation.
Solution Approach 2:
The electrical connections are made in advance during the rough-in stage, allowing the building surface to be completed first. The junction box can then be adjusted to achieve proper alignment with the finished surface, eliminating the need to wait for surface completion before making electrical connections.
4Manufacturing precision
If the junction box allows adjustment relative to the wall, then alignment with the building surface can be achieved, but the adjustment mechanism adds complexity to the device
Solution Approach 1:
The adjustment mechanism uses simple threaded slots that allow the junction box to move along the wall stud. This dynamic system provides alignment adjustment capability while maintaining relative structural simplicity through the use of basic threading and slot geometry.
Data Source
AI summary
An adjustable junction box is provided that allows a technician to selectively adjust the distance between an outer surface of the junction box and an outer surface of a stud to which the junction box is interconnected. A selectively-removable cover is also provided that allows an outlet, for example, to be interconnected to a power supply and later removed for inspection.