Adjustable Mud Ring With External Locking Sleeve
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Solution Overview
Problem
Existing solutions for adjusting electrical outlet box covers to accommodate varying wall thicknesses are either impractical, require exposure to live wires, or compromise the grounding path, and often necessitate long screws that interfere with wiring.
Innovation Solution
An adjustable cover with a mounting plate, extension sleeve, and locking device that allows for external adjustment without affecting the box's position, providing a secure grounding path and eliminating the need for long screws by using a fastener that locks the extension sleeve externally.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a threadably mounted extension sleeve is used to adjust the box position, then the box can be adjusted after wall material is installed, but the installer must make adjustments from inside the box which exposes the installer to live wires
Solution Approach 1:
The patent inverts the adjustment mechanism by moving the fastener to the outside of the box while keeping the extension sleeve attachment point inside. This allows the installer to make adjustments from the safe outside position rather than reaching inside the box where live wires are located. The fastener extends through the box wall, enabling external operation of the adjustment mechanism.
Solution Approach 2:
The fastener acts as an intermediary that connects the external adjustment mechanism to the internal extension sleeve. By using this intermediary component that passes through the box wall, the system allows force and motion to be transmitted from the safe external environment to the internal adjustment point without requiring direct access to the hazardous interior.
2Adaptability or versatility
If long screws are used to mount the extension sleeve, then the extension sleeve can be adjusted over a larger range, but the screws project into the box and interfere with the box's wiring
Solution Approach 1:
The mounting system is segmented into two separate functions: the extension sleeve provides the adjustment range and positioning, while the fastener provides the securing mechanism. This segmentation allows the fastener to be positioned optimally for securing without interfering with wiring, while the extension sleeve extends to provide the necessary adjustment range.
Solution Approach 2:
The harmful function of the screw projecting into the box is extracted and eliminated. Instead of using a single long screw that both mounts and adjusts, the patent separates these functions: the extension sleeve handles adjustment while a shorter fastener handles mounting, removing the interference problem while preserving the adjustment capability.
3Device complexity
If a single screw is used to position the extension sleeve, then the structure is simple, but the ground path from the electric device to the box passes through the screw which can cause grounding issues if the screw is loose
Solution Approach 1:
The patent merges the grounding function with the mechanical fastening function by making the fastener itself the grounding path. The fastener is designed to provide both structural attachment and electrical continuity, eliminating the need for a separate grounding path while ensuring reliable grounding through the robust fastening connection.
Solution Approach 2:
The fastener is designed with multi-functionality, serving both as the mechanical mounting element and as the grounding path. This universal component performs multiple functions simultaneously: securing the extension sleeve, providing structural support, and establishing the electrical ground connection, thereby simplifying the overall structure while improving reliability.
4Adaptability or versatility
If the box is adjusted to accommodate varying wall thicknesses, then the cover can be flush with the wall, but the position of the box itself changes which may affect wiring and device installation
Solution Approach 1:
The system is segmented into the fixed box and the adjustable extension sleeve. This segmentation allows the extension sleeve to absorb all adjustment movements while the box remains stationary, enabling wall thickness accommodation without box displacement and preventing harmful effects on wiring and device installation.
Data Source
AI summary
This invention pertains to an adjustable cover for an electrical outlet box. The cover is configured having a generally planar mounting plate with a collar surrounding an opening through this mounting plate. An extension sleeve moves within this opening and adjacent the collar. At least one fastener is located adjacent the opening and is movable between a locked position and an unlocked position. The fastener operates a locking device that engages a wedge against the extension sleeve when the fastener is in the locked position and disengages a wedge against the extension sleeve when the fastener is in the unlocked position.