Concrete Wall Junction 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 both 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, ensuring compliance with building codes and aesthetic satisfaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional outlet boxes are installed in concrete walls with cover plates, then the structural and safety functions 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 visual distraction while maintaining the functional enclosure. The outlet box is designed to be directly mounted in the concrete wall with the electrical component protruding flush through the wall surface, thereby taking out the harmful aesthetic element (cover plate) while preserving structural integrity and safety functions.
2Ease of manufacture
If outlet boxes are mounted to studs in studded walls, then the installation method is simple and well-established, but the application to concrete walls is limited and requires adaptation
Solution Approach 1:
The invention creates a universal mounting system that can be applied to both studded walls and concrete walls. The outlet box assembly is designed with mounting mechanisms that adapt to different wall types - it can be mounted to studs in traditional construction or directly embedded in concrete walls using chemical anchors or mechanical fasteners, thereby achieving multi-functionality and broad applicability across different construction methods.
3Reliability
If cover plates are used to close the open front of outlet boxes, then the enclosure function is achieved, but the visual distraction and aesthetic impact increase
Solution Approach 1:
The invention converts the potentially harmful aesthetic impact of the outlet box opening into a beneficial feature by designing the electrical component (outlet or switch) to protrude flush through the wall surface. The opening that would normally require a cover plate is transformed into a functional and aesthetic feature where the component itself becomes the finished element, eliminating visual distraction while maintaining enclosure and protection functions.
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.