Adjustable Mud Ring With External Locking Wedges
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Solution Overview
Problem
Existing electrical outlet box covers face challenges in maintaining flush installation with varying drywall thicknesses or additional wall materials, as existing solutions require adjustments that expose installers to live wires, use long screws interfering with wiring, and lack a solid ground path or rigid locking mechanism.
Innovation Solution
An adjustable cover with a mounting plate, extension sleeve, and locking devices featuring L-shaped wedges and fasteners that allow for external adjustments without affecting the box's position, providing a secure ground path and eliminating the need for long screws, enabling adjustments post-wall installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If adjustments are made from inside the box, then the extension sleeve can be adjusted, but the installer is exposed to live wires
Solution Approach 1:
The patent inverts the adjustment approach by allowing adjustments to be made from outside the box rather than from inside. The extension sleeve is adjusted externally through the cover opening, eliminating installer exposure to live wires while maintaining full adjustability for accommodating varying wall thicknesses and materials.
2Adaptability or versatility
If long screws are used to mount the extension sleeve, then the sleeve can be adjusted, but the screws interfere with the box's wiring
Solution Approach 1:
The patent extracts the adjustment function from the box's internal wiring area by mounting the extension sleeve to the cover rather than to the box itself. This separation allows the sleeve to be adjusted externally without requiring long screws that would penetrate into the box and interfere with the wiring.
3Adaptability or versatility
If the box position is adjusted, then the outlet position changes, but the box's position relative to the wall changes
Solution Approach 1:
The patent segments the adjustment function into two independent parts: the box remains fixed in its installed position, while the extension sleeve mounted to the cover provides the adjustable extension. This segmentation allows the outlet position to be adjusted relative to the wall without moving the box itself, maintaining proper wiring connections.
4Adaptability or versatility
If a rigid locking mechanism is not used, then the extension sleeve can be adjusted, but the screw may become loose
Solution Approach 1:
The patent implements a dynamic locking system where the extension sleeve can be freely adjusted to any position and then rigidly locked using set screws. The locking mechanism transitions from a movable state during adjustment to a fixed rigid state when locked, ensuring both adjustability and reliable grounding without compromising either function.
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 wedges against the extension sleeve when the fastener is in the locked position and disengages wedges against the extension sleeve when the fastener is in the unlocked position.