Adjustable Electrical Outlet Box Assembly with Sliding Bracket
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrical outlet boxes are difficult to position correctly with respect to the wall surface due to varying drywall thicknesses, and securing them to a stud limits placement flexibility.
Innovation Solution
A fully adjustable outlet box assembly featuring a sliding bracket and brace support plate, with an adjustment screw that allows the outlet box to be positioned flush with the wall surface, enabling secure mounting between studs while allowing placement at any desired location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the outlet box is fastened to a wall stud before drywall is applied, then the outlet box is stable and secured, but the positioning is limited based on the locations of available studs
Solution Approach 1:
The mounting system is divided into separate components: a brace that attaches to studs, a sliding bracket that moves along the brace, and the outlet box. This segmentation allows the outlet box to be positioned independently at any location between studs while the brace remains firmly attached to the wall structure, resolving the contradiction between stability and positioning flexibility.
Solution Approach 2:
The sliding bracket acts as an intermediary between the fixed brace (attached to studs) and the movable outlet box. It transfers the stable support from the brace to the outlet box while allowing positional adjustment, enabling the outlet box to be secured stably yet positioned flexibly at any desired location between studs.
2Reliability
If conventional outlet boxes are installed before drywall is applied, then the outlet box can be secured to studs, but it is difficult to position correctly with respect to the eventual wall surface due to varying drywall thicknesses
Solution Approach 1:
The sliding bracket is designed to be movable along the brace, allowing dynamic adjustment of the outlet box position after installation. This enables precise positioning relative to the wall surface even when drywall thickness varies, while the outlet box remains securely attached to the brace throughout the adjustment process.
Solution Approach 2:
The brace is pre-installed and secured to the studs before the outlet box is mounted. This preliminary action establishes a stable reference structure that allows subsequent precise positioning of the outlet box using the sliding bracket, ensuring both securing reliability and positioning precision.
3Adaptability or versatility
If an adjustable mechanism is added to the outlet box, then positioning flexibility is improved, but the device complexity increases
Solution Approach 1:
The adjustment mechanism is segmented into simple, discrete components: a sliding bracket with a slot and an adjustment screw. This segmentation keeps each component simple and easy to manufacture while collectively providing continuous positioning flexibility along the brace length.
Solution Approach 2:
The sliding bracket serves as a simple intermediary component that provides adjustment capability without requiring complex mechanisms. The bracket's slot accommodates the adjustment screw, creating a straightforward mechanical system that enables positioning flexibility while maintaining simplicity in both design and manufacturing.
Data Source
AI summary
An electrical outlet box assembly for mounting an electrical device within a wall or floor. The assembly includes an outlet box, a sliding bracket, and a brace. The brace is mounted between two studs in a wall or joists in a floor. The outlet box may be positioned at almost any point along the length of the brace. Further, an adjustment screw, accessible from the front of the box, is integrated with the sliding bracket and outlet box such that rotation of the screw adjusts the location of the outlet box in relation to the sliding bracket. This adjustment permits a user to adjust the position of the outlet box so that it is substantially flush with the wall or floor surface.