Adjustable Electrical Outlet Box Assembly with Sliding Bracket
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Solution Overview
Problem
Conventional adjustable outlet boxes face challenges in being securely fastened to studs and have complex designs that increase production costs, making it difficult to achieve a flush installation with varying drywall thicknesses.
Innovation Solution
An adjustable outlet box assembly featuring a metal box with a sliding bracket and an externally accessible adjustment screw, allowing for easy alignment with the wall surface without recesses in the sidewall, which simplifies construction and maintains usable space within the box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional outlet boxes are fastened to wall studs before drywall installation, then the boxes can be securely attached to the structure, but it becomes difficult to position them correctly with respect to the eventual wall surface due to varying drywall thicknesses
Solution Approach 1:
The outlet box is made adjustable through a sliding mechanism on the bracket, allowing the box to be dynamically repositioned after drywall installation to achieve proper alignment with the wall surface, while maintaining secure attachment to the stud
2Manufacturing precision
If adjustable outlet boxes include a mechanism for adjusting the face of the outlet box with respect to the wall surface, then positioning accuracy is improved, but the design becomes complex which increases production cost
Solution Approach 1:
The bracket is divided into separate functional components: a mounting portion for attachment to the stud and an adjustment portion with sliding mechanism for the outlet box, allowing independent optimization of each function while maintaining overall simplicity
Solution Approach 2:
The bracket acts as an intermediary element between the fixed stud mounting and the adjustable outlet box, providing a simple sliding mechanism that enables precise positioning without complex internal adjustments within the box itself
3Shape
If the adjusting screw is recessed within the sidewall of the electrical box, then the appearance is improved, but construction complexity increases as recesses or channels must be formed in the sidewall
Solution Approach 1:
The adjusting screw mechanism is extracted from the interior of the electrical box and placed on the exterior, eliminating the need to form recesses or channels in the box sidewalls while maintaining adjustability functionality
4Reliability
If the adjusting screw is located inside the electrical box, then the mechanism is protected, but usable space within the box interior is reduced for electrical devices and wiring
Solution Approach 1:
The adjusting screw and adjustment mechanism are relocated to the exterior of the electrical box, completely separating the adjustment function from the box interior, thereby maximizing usable space for electrical devices and wiring while keeping the adjustment mechanism accessible and protected on the exterior
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables secure fastening to studs, reduces production complexity and costs, and allows for post-installation adjustment of the outlet box to ensure flush alignment with the wall surface, preserving interior space and simplifying manufacturing through sheet metal stamping and bending.
Implementation Method 1
U-shaped channels extending outward from a sidewall of the electrical box hold a bracket that is slidable with respect to the box
Implementation Method 2
The adjustable outlet box assembly is provided with an adjusting screw that is located outside of the electrical box portion of the assembly
Data Source
AI summary
An adjustable electrical outlet box assembly for mounting a duplex receptacle or similar electrical device within a wall. The adjustable box assembly includes a metal outlet box and a bracket that can slide 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 the stud it is secured to and thereby adjust the face of the outlet box so that it is substantially flush with the wall surface. The bracket portion of the adjustable box assembly, which may be simply stamped and formed from sheet metal, provides a front plate for securing to the front of a stud and a side plate having widely spaced 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.