Dual-Hinge Recessed Electrical Box for Flexible Orientation
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Solution Overview
Problem
Existing recessed electrical boxes require multiple types (horizontal, vertical, single-gang, double-gang) to be stocked, leading to a large and costly inventory due to limited configurational flexibility, and they are not designed to allow cord passage when the cover is closed.
Innovation Solution
A dual-hinge recessed outdoor electrical outlet box with a unitary body and cover that can be oriented horizontally or vertically, featuring interchangeable hinge assemblies and a design that allows cord passage even when the cover is closed, minimizing water ingress with a lip and gasket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple types of recessed electrical boxes (horizontal, vertical, single-gang, double-gang) are stocked to meet different installation needs, then all configuration requirements can be satisfied, but inventory complexity and storage costs increase substantially
Solution Approach 1:
The box is designed with a universal configuration capability through interchangeable hinge assemblies. The same box body can be equipped with different hinge assemblies (first hinge assembly for horizontal opening, second hinge assembly for vertical opening) to adapt to different installation orientations and gang configurations, eliminating the need to stock multiple specialized box types.
Solution Approach 2:
The hinge system is segmented into interchangeable assemblies that can be independently selected and attached. The first hinge assembly and second hinge assembly are separate, replaceable components that allow the box to be reconfigured for different opening directions without replacing the entire box structure.
2Device complexity
If the cover is designed to open only in a fixed orientation (horizontal or vertical), then the hinge structure is simple, but the box cannot adapt to different installation orientations
Solution Approach 1:
The hinge configuration is made dynamic and adjustable rather than fixed. The interchangeable hinge assemblies allow the box to change its opening orientation from horizontal to vertical (or vice versa) by simply replacing the hinge assembly, providing adaptability without permanently complicating the structure.
3Object-affected harmful factors
If the cover is designed to provide full weatherproofing when closed, then water ingress is minimized, but cord passage through the closed cover becomes impossible
Solution Approach 1:
A cord passage mechanism acts as an intermediary element that allows cords to pass through the closed cover while maintaining weatherproofing. The mechanism includes a passage through the cover and a weatherproof seal or gasket that prevents water ingress while permitting cord traversal, thus mediating between the conflicting requirements of sealing and accessibility.
Data Source
AI summary
A recessed electrical outlet box which includes a body that is selectably connected to a cover by either a first or a second hinge assembly. The body includes a back wall, a face plate, a side wall and an interior, wherein the side wall extends between the back wall and face plate and the face plate has an opening for accessing the interior. The interior includes a recessed pair of bosses and a pair of mounting holes, which can be used for mounting electrical devices in the interior. The first and second hinge assemblies have a first hinge axis and a second hinge axis, respectively, and are attached to the face plate and cover so that the first hinge axis is substantially perpendicular to the second hinge axis.