Non-Metallic Electrical Box Assembly for Concrete Floors
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Solution Overview
Problem
Conventional metal electrical boxes for concrete installations are prone to corrosion from moisture, costly to manufacture, and can be crushed by heavy concrete pours, lacking the necessary strength and adaptability for varying floor thicknesses.
Innovation Solution
A non-metallic electrical box assembly made from concrete with integral sockets, a mounting bracket, back plate, cover plate, and removable threaded blanks, featuring a concrete can with stiffening ribs and adjustable spacers for height adaptation, constructed from durable and corrosion-resistant materials like PVC.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal electrical boxes are used for concrete installation, then electrical conductivity and structural strength are improved, but corrosion resistance deteriorates due to moisture and water seepage
Solution Approach 1:
The patent employs composite construction by combining a non-metallic concrete can (resistant to corrosion) with metal mounting brackets and receptacles (providing structural strength and electrical conductivity). This composite approach allows each material to contribute its advantageous properties while mitigating its disadvantages.
Solution Approach 2:
The patent replaces expensive, durable metal boxes with a more economical non-metallic concrete can that achieves the necessary durability through composite construction and design features like stiffening ribs, effectively creating a cost-optimized solution that maintains reliability.
2Strength
If metal electrical boxes are used, then structural strength is improved, but manufacturing cost increases due to high metal prices and substantial secondary operations
Solution Approach 1:
The patent substitutes expensive metal boxes requiring welding and assembly operations with a non-metallic concrete can that can be manufactured more economically through molding or casting processes, significantly reducing manufacturing complexity and cost.
Solution Approach 2:
By using a non-metallic concrete can as the primary structure and adding metal components only where absolutely necessary for electrical and mounting functions, the patent reduces overall material cost while maintaining required structural integrity.
3Ease of manufacture
If wall thickness of metal electrical boxes is reduced to minimize cost, then manufacturing cost decreases, but strength deteriorates leading to crushing by heavy concrete
Solution Approach 1:
The patent incorporates stiffening ribs on the concrete can that provide localized reinforcement at critical stress points, allowing the overall wall thickness to remain economical while ensuring sufficient crush resistance where needed during concrete pouring.
Solution Approach 2:
The non-metallic concrete can with integrated stiffening features provides an inherently stronger and more crush-resistant structure compared to thin-walled metal boxes, eliminating the need to choose between cost and strength.
4Device complexity
If fixed height electrical boxes are used, then device complexity is reduced, but adaptability deteriorates for varying floor thicknesses with different coverings
Solution Approach 1:
The patent incorporates an adjustable mounting mechanism with a mounting bracket and positionable fasteners that allow the electrical box to be positioned at various heights within the concrete can, enabling adaptation to different floor covering thicknesses while maintaining a relatively simple overall structure.
Data Source
AI summary
An electrical box assembly for concrete poured floors. The electrical box assembly includes a concrete can with an open end and a plurality of hubs with integral sockets for connection of electrical conduit thereto. Plugs are provided for closing off unused sockets. The electrical box assembly includes a mounting bracket for installation on the open end of the can, a duplex receptacle, a back plate and a cover plate. The back plate provides a seal between the mounting bracket and the cover plate. Removable threaded blanks are included for sealing the openings in the cover plate in order to gain access to the plug-ins on the duplex receptacle.