Concrete Wall Electrical Box Assembly for Flush Outlet Installation
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Solution Overview
Problem
Conventional electrical outlet boxes in concrete walls require visible cover plates, which are aesthetically undesirable and violate the refined appearance sought in high-end construction, while also posing a challenge in complying with building codes.
Innovation Solution
A method and apparatus for installing electrical outlets or switches directly into concrete walls without visible cover plates, using a junction box assembly with a secondary plate and removable blank that allows for flush mounting and secure fastening to the concrete form, followed by pouring concrete around it.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional outlet boxes are installed in concrete walls with cover plates, then the structural integrity and code compliance are maintained, but the aesthetic appearance deteriorates due to visible cover plates
Solution Approach 1:
The invention extracts and removes the cover plate from the outlet box assembly, eliminating the aesthetic defect while preserving the functional enclosure. The outlet box is designed to be directly embedded in the concrete wall without requiring a separate cover plate, thus taking out the problematic component while maintaining structural integrity and code compliance.
2Shape
If outlet boxes are embedded directly in concrete walls without cover plates, then the aesthetic appearance improves, but the ease of installation and code compliance become problematic
Solution Approach 1:
The outlet box is designed with pre-integrated mounting features including embedded anchor points and a integrated cover that is removed prior to concrete pouring. This preliminary design allows the box to be easily installed in the concrete form before the concrete is poured, ensuring both aesthetic appearance and ease of installation while maintaining code compliance.
3Shape
If a integrated cover design is used that is removed before pouring concrete, then the aesthetic appearance and ease of installation are improved, but the device complexity increases
Solution Approach 1:
The outlet box assembly is segmented into distinct functional components: the main box body with mounting features, the integrated cover that is removed before pouring, and the concrete-embedded mounting structure. This segmentation allows each component to be optimized independently, improving aesthetics and installation ease while managing complexity through modular design.
Data Source
AI summary
Methods for molding an electrical socket into concrete during the concrete pouring process are disclosed. The method includes mounting an electrical junction box assembly to a concrete form. The electrical junction box has a closure plate that defines a first through hole configured to receive an electrical switch or electrical outlet, a secondary plate mounted directly to the closure plate, and a removable blank seated in the second through hole and having a bolt extending through the removable blank and protruding forward a distance sufficient to be received in and protrude from the hole in the concrete form. The secondary plate has a forward protruding flange defining a second through hole aligned with the first through hole. Then, the method includes pouring concrete into the concrete form, thereby surrounding the electrical junction box with concrete, and after the concrete is set, removing the concrete form and the removable blank.