Flexible Edge Adapter for Electrical Box Ring Retention

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Solution Overview

Problem

Existing electrical box extenders pose health and safety risks due to their sharp inner edges, which can damage circuit wires and injure individuals, and fail to securely lock in place during servicing, leading to potential electrical faults and hazards.

Innovation Solution

A flexible edge adapter with a smooth, flame-retardant body that encloses the sharp edge of the extension ring, featuring retention flanges to securely lock onto the electrical box extender and prevent dislodgment, while providing insulation to protect wires and individuals from harm.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If a metal extension ring is used to extend the electrical box, then the box fill capacity is expanded and the box becomes flush with the wall surface, but the sharp inner edge of the extension ring cuts into circuit wires causing electrical circuit faults

Engineering Contradiction:

Improvebox fill capacityVSAvoidwire damage from sharp edges

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

A flexible adapter is introduced as an intermediary component between the metal extension ring and the circuit wires. The adapter's smooth inner surface acts as a mediator that eliminates the harmful sharp edges while maintaining the structural function of the extension ring, thereby protecting the wires from cutting damage

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The adapter is made of flexible material that can conform to the inner surface of the metal extension ring. This flexible shell covers the sharp edges completely while maintaining the box's structural integrity and fill capacity, solving the wire damage problem without sacrificing the extension function

Inventive Principle:

Principle #30Flexible shells and thin films

2Volume of moving object

If a metal extension ring is used to extend the electrical box, then the box fill capacity is expanded, but the exposed sharp inner edge poses health and safety risks to electricians and individuals who come into contact with it

Engineering Contradiction:

Improvebox fill capacityVSAvoidinjury risk from sharp edges

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The flexible adapter serves as a protective intermediary layer between the sharp metal edges and human contact. It transforms the hazardous sharp edges into a safe, smooth surface that protects electricians and individuals during installation, adjustment, and repair operations

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The flexible material forms a protective shell over the sharp edges, providing tactile feedback and physical protection against injury while maintaining the structural function of the extension ring

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of manufacture

If a standard extension ring is used without additional retention features, then the installation is simple, but the extension ring can become dislodged during servicing or troubleshooting of electrical circuits

Engineering Contradiction:

Improveinstallation simplicityVSAvoidretention stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The adapter is designed as a separate, modular component that can be independently installed onto the extension ring. This segmentation allows for simple installation while providing enhanced retention features that prevent dislodgment during servicing

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flexible adapter is designed to nest within or around the metal extension ring, creating a layered structure where the adapter provides retention features (such as ribs or engagement points) that secure the assembly in place without complicating the overall installation process

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS12021362B2Edge adapter for electrical box extension rings

Publication Date: 2024.06.25 NICHOLS ROBERT G

AI summary

An edge adapter for electrical box extension rings includes a flexible adapter body enclosing and defines an adapter channel, the flexible adapter body has a continuous sidewall defining at least four sides, each side having an inner wall surface facing the adapter channel and an outer wall surface opposite to the inner wall surface. A first pair of retention flanges are adjacent one another and disposed on and radially projecting from the outer wall surface on a first side of the adapter body. A second pair of retention flanges are adjacent one another and disposed on and radially projecting from the outer wall surface on the first side of the adapter body, the first pair of retention flanges and the second pair of retention flanges together defining a first retention slot shaped and dimensioned to receive a first inner wall of an electrical box extension ring. A third pair of retention flanges are adjacent one another and disposed on and radially projecting from the outer wall surface on the second side of the adapter body opposite the first side. A fourth pair of retention flanges are adjacent one another and disposed on and radially projecting from the outer wall surface on the second side of the adapter body, the third pair of retention flanges and the fourth pair of retention flanges together defining a second retention slot shaped and dimensioned to receive a second inner wall of the electrical box extension ring.