Adjustable Outlet Box Bracket Asymmetry
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Solution Overview
Problem
Conventional adjustable outlet boxes face challenges in achieving stable and predictable installation due to asymmetrical torque application, leading to potential skewing of the outlet box face with respect to the wall surface, and often have complex designs that increase production costs.
Innovation Solution
An adjustable outlet box assembly featuring a bracket with a rearwardly located integral flange that securely engages the adjustment screw, allowing for orthogonal alignment and stabilization, combined with the use of polymeric materials for manufacturing, which simplifies design and reduces production costs while ensuring secure fastening to studs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional adjustable outlet boxes are used, then the outlet box can be adjusted to be flush with the wall surface, but the installation becomes unstable and unpredictable due to asymmetrical torque application causing skewing
Solution Approach 1:
The patent applies asymmetry by positioning the adjustment screw and its engagement point intentionally off-center relative to the bracket's centerline. This asymmetric configuration allows the adjustment mechanism to function properly while the overall symmetric bracket structure maintains stability. The asymmetric screw placement enables torque application without causing rotational skewing of the outlet box, as the screw engages the adjustable arm in a way that translates rotational motion into linear adjustment without inducing unwanted rotation.
Solution Approach 2:
The patent implements preliminary action by providing pre-drilled holes in the bracket that align with the adjustment screw location. These pre-prepared features guide the installer to apply torque at the correct position and orientation before final assembly, ensuring proper alignment and preventing skewing during the adjustment process. The pre-configured geometric relationships between the screw, bracket, and outlet box establish stable alignment conditions prior to installation.
2Adaptability or versatility
If complex bracket designs are used to provide adjustment capability, then the outlet box can be adjusted to be flush with the wall, but the production cost increases
Solution Approach 1:
The patent applies segmentation by dividing the bracket into distinct functional components: a main bracket body for mounting to the stud, an adjustable arm that holds the outlet box, and an adjustment screw mechanism. This segmentation allows each component to be manufactured separately using simple processes and then assembled, reducing overall complexity and production cost while maintaining full adjustment capability.
Solution Approach 2:
The patent implements universality by designing the bracket to perform multiple functions with a single integrated structure. The bracket simultaneously provides mounting attachment to the stud, support for the outlet box, and the adjustment mechanism for achieving flush alignment. This multi-functionality eliminates the need for separate adjustment devices or complex mechanisms, simplifying manufacturing while providing comprehensive adjustment capability.
Data Source
AI summary
An adjustable outlet box assembly for mounting a receptacle or similar electrical device within a wall. The adjustable box includes an outlet box and a bracket that slides with respect to the box. An adjustment screw, accessible from the front of the assembly, can be rotated to move the box with respect to a stud to which the outlet box is secured thereby allowing adjustment of the outlet box face so that it is flush with the wall surface. The bracket provides a front plate for securing to the front of a stud and a side plate having ears for securing to the side of a stud. The adjustment screw engages straps that are bent outwards from the side plate to enable the bracket to slide with respect to the outlet box as well as a rearwardly located integral flange to which the adjustment screw is introduced upon tightening thereof.