Compressible Spacing Member for Electrical Box Alignment
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Solution Overview
Problem
Wall mounted electrical box assemblies often suffer from misalignment issues during installation, making it difficult to achieve a flush fit between the face plate and the wall surface, requiring extensive repositioning and effort to correct misalignments.
Innovation Solution
Incorporation of a compressible spacing member between the terminal electrical unit mounting yoke and the electrical box mounts, allowing for adjustable positioning and compression to ensure perfect alignment and flush mounting of the face plate against the wall surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional rigid mounting methods are used, then structural stability is maintained, but alignment precision deteriorates due to inability to compensate for installation variations
Solution Approach 1:
The patent applies parameter changes by using a compressible spacing member that can change its physical dimension (compression) to adjust the mounting depth and alignment of the terminal electrical unit. This allows the system to adapt to variations in wall surface irregularities and achieve precise alignment without requiring complex adjustment mechanisms.
Solution Approach 2:
The compressible spacing member acts as an intermediary element between the terminal electrical unit and the electrical box. It mediates the connection by providing a compliant interface that absorbs alignment discrepancies and enables flush mounting of the face plate against the wall surface.
2Manufacturing precision
If compressible spacing members are used, then alignment precision is improved, but device complexity increases due to additional components
Solution Approach 1:
The compressible spacing member utilizes material compressibility as a variable parameter to achieve alignment adjustment. By selecting materials with appropriate compressive properties, the system can accommodate a range of installation conditions with a single component design, avoiding the need for multiple different components.
Solution Approach 2:
The spacing member is designed with specific local properties (compressibility in the mounting direction) while maintaining structural integrity in other aspects. This localized application of material properties allows the component to perform its alignment function without requiring the entire mounting system to be complex.
3Manufacturing precision
If multiple repositioning operations are performed to achieve flush mounting, then alignment precision can be improved, but installation time increases significantly
Solution Approach 1:
The compressible spacing member is pre-installed in the mounting position before the terminal electrical unit is secured. This preliminary placement establishes the correct alignment geometry in advance, allowing the installer to achieve flush mounting in a single operation rather than requiring multiple repositioning cycles.
Solution Approach 2:
The compressible spacing member performs self-adjustment through its compression characteristics. As the terminal electrical unit is mounted and compressed against the spacing member, the spacing member automatically adjusts its length to achieve the correct alignment, eliminating the need for manual measurement and repeated repositioning by the installer.
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
Facilitates efficient and precise installation of terminal electrical units with minimal effort, ensuring a flush and even placement of the face plate against the wall surface, reducing installation time and correcting misalignment issues effectively.
Implementation Method 1
Incorporation of a compressible spacing member between the terminal electrical unit mounting yoke and the electrical box mounts, allowing for adjustable positioning and compression to ensure perfect alignment
Data Source
AI summary
The ability to wall mount switching and power outlets expeditiously and uniformly to walled surfaces may be professionally achieved through the use of wedged resilient spacing members positioned between the switching or outlet units and their mounts. The spacing members provide a perfected flush and even installation of the switching and power outlets to the abutting wall surface. The compressed resilient spacing members compensate for what normally would be flawed installations.