Adjustable Electrical Device Yoke for Flush Wall Mounting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrical devices often get improperly installed in walls, leading to issues like gaps between the device and faceplate, safety concerns, and non-compliance with the National Electrical Code, due to misalignment or improper depth of installation.
Innovation Solution
An adjustable mounting system for electrical devices that allows for adjustment of the yoke's depth and position relative to the electrical box, using mechanisms like screw threads, straps, and friction to ensure proper alignment and support, enabling the device to be flush with the wall face.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the electrical box is installed too far backward into the wall, then the electrical device cannot be flush with the wall face, but moving the electrical device forward creates gaps between the device and faceplate
Solution Approach 1:
The yoke is made adjustable rather than fixed, allowing it to move forward or backward relative to the electrical device housing. This dynamic adjustment enables the yoke to compensate for improper electrical box installation depth, allowing the device to be flush with the wall face while maintaining proper alignment with the faceplate.
Solution Approach 2:
The mounting depth parameter of the yoke is made variable through adjustable mechanisms (screw threads, friction clips, or cam actuators). By changing this parameter, the system can adapt to different electrical box installation depths and achieve proper alignment even when the box is installed too far backward.
2Manufacturing precision
If the yoke is made adjustable to allow depth adjustment, then proper alignment can be achieved, but the device complexity increases
Solution Approach 1:
The mounting system is divided into separate functional components: the electrical device housing, the adjustable yoke, and the adjustment mechanism. This segmentation allows each component to be optimized independently and simplifies the overall design by assigning specific functions to discrete elements.
Solution Approach 2:
The adjustment mechanism is designed to be self-contained within the yoke assembly, using internal components like screw threads or friction clips that automatically maintain the yoke's position once adjusted. This self-service design reduces the need for additional external adjustment mechanisms and simplifies the overall structure.
3Device complexity
If conventional fixed mounting is used, then the device structure is simple, but improper installation leads to safety concerns and code non-compliance
Solution Approach 1:
The fixed yoke is replaced with an adjustable yoke that can dynamically adapt to improper electrical box installations. This ensures reliable, code-compliant installation even when the electrical box is installed too far backward, eliminating safety concerns associated with fixed mounting.
Solution Approach 2:
The adjustable mounting system proactively compensates for potential installation errors before they result in non-compliant or unsafe conditions. By allowing adjustment, the system prevents the harmful effects of improper box installation depth, ensuring the device can always be properly aligned and secured.
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 adjustable mounting system ensures the electrical device is securely and correctly aligned with the wall, preventing gaps and safety issues, while allowing for proper installation even if the electrical box is misaligned or too far back, thus enhancing both aesthetics and safety.
Implementation Method 1
adjusting a screw threadedly coupled to at least two first brackets, one each coupled to one of each of the two yokes
Implementation Method 2
using mechanisms like screw threads, straps, and friction to ensure proper alignment and support
Data Source
AI summary
An adjustably mountable electrical device with one or more yokes coupled to the electrical device, at least one electrically conductive strap, and an electrical device face, wherein a distance between the electrical device face and at least one of the yoke, the strap and an electrical box mounting screw aperture is adjustable after the electrical device is mounted to the electrical box. The system may comprise mounting flanges that may have threaded hubs or the system may further comprise an electric device having front and back shells moveable on a track in response to depression of a button allowing for movement of the back shell so that the electric device may be mounted having its face coplanar with a front wall surface.