Appliance Outlet Box With Configurable Drainage and Acoustic Isolation
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Solution Overview
Problem
Existing appliance outlet boxes lack cost-effective drainage options for condensate and temperature/pressure relief drain lines, do not facilitate easy configuration of drain funnels with outlet box drains and inlet piping, fail to provide acoustic isolation, and lack structural support and rigid brackets.
Innovation Solution
The outlet box assembly includes a configurable housing with socket portions for conduits, a funnel assembly for directing fluid flow, a collet assembly for secure plumbing fittings, elastomeric gaskets for noise and vibration isolation, and intumescent fire wrap support brackets for structural reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If existing appliance outlet boxes are used, then basic installation functionality is provided, but drainage options for condensate and temperature/pressure relief drain lines are not cost-effective
Solution Approach 1:
The outlet box is divided into multiple wall portions (first wall portion, second wall portion, third wall portion) with separate socket portions for different drainage functions. This segmentation allows independent configuration of condensate drain and temperature/pressure relief drain lines, providing cost-effective and flexible drainage options for different appliance requirements.
Solution Approach 2:
The outlet box assembly is designed with multiple socket portions that can accommodate various conduit types and configurations. The first socket portion receives condensate drain conduit while the second socket portion receives temperature/pressure relief drain conduit, creating a universal solution that handles multiple drainage functions within a single integrated structure.
2Ease of operation
If existing appliance outlet boxes are used, then basic mounting is provided, but easy configuration of drain funnels with outlet box drains and inlet piping is not achieved
Solution Approach 1:
The funnel assembly is pre-configured with a stationary/fixed funnel portion that is integrated into the outlet box housing during manufacturing. This preliminary action eliminates the need for field assembly of funnel components, making drain funnel configuration easy while reducing overall system complexity.
Solution Approach 2:
The funnel assembly merges the stationary/fixed funnel portion with the outlet box housing structure, creating an integrated drainage path. This combination simplifies the configuration process by eliminating separate funnel installation steps while maintaining functional complexity for proper drainage flow direction.
3Object-affected harmful factors
If existing appliance outlet boxes are used, then basic structural support is provided, but acoustic isolation to reduce plumbing noise and vibration transfer is not achieved
Solution Approach 1:
An elastomeric gasket is introduced as an intermediary element between the outlet box housing and the mounting bracket. This gasket provides acoustic isolation to reduce plumbing noise and vibration transmission to occupied spaces, while maintaining the structural connection functionality without adding significant complexity to the overall structure.
4Strength
If existing appliance outlet boxes are used, then basic installation support is provided, but adequate structural support with rigid brackets is not achieved
Solution Approach 1:
The mounting bracket is constructed as a composite structure combining a rigid bracket portion for structural support with an elastomeric gasket for isolation. This composite design provides adequate structural support strength while integrating noise and vibration reduction functionality without excessive complexity.
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 assembly enhances installation ease and reduces noise transmission, provides flexible orientation options, and offers robust structural support for appliances like water heaters, improving installation quality and efficiency.
Implementation Method 1
an elastomeric gasket of a predetermined thickness and a predetermined stiffness to isolate the plumbing fitting and reduce transmission of noise and vibration
Implementation Method 2
an elastomeric gasket of a predetermined thickness and a predetermined stiffness to isolate the plumbing fitting and reduce transmission of noise and vibration
Data Source
AI summary
An outlet box assembly includes an outlet box housing, configurable between a first and second orientation, and a funnel assembly. The outlet box housing includes a first wall portion and a second wall portion. The first wall portion includes a first socket portion, including a first knock out portion, and at least one through hole. The first knock out portion includes a first knock out body and an area of weakening. The through hole attaches a plumbing fitting to the first wall portion. The second wall portion includes a second socket portion including a second knock out portion including a second knock out body and an area of weakening. The funnel assembly has a fixed funnel portion and a funnel cover configured to be removably attached to the fixed funnel portion. The funnel assembly is configured to direct fluid to the first or second socket portion.