Adjustable-Depth Electrical Box Sleeve for Flush Wall Alignment
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Solution Overview
Problem
Existing electrical boxes often require adjustment in depth relative to support structures after installation to ensure flush alignment with wall coverings, and existing solutions lack flexibility in accommodating varying wall depths and providing accessible rear termination of electrical devices.
Innovation Solution
An electrical box assembly with an extendable sleeve and adjustable back plate, allowing for axial movement within the electrical box housing, and a removable back plate for accessible rear termination, accommodating different wall depths through a bendable far side support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrical boxes are installed with fixed depth, then installation process is simple, but they cannot accommodate varying wall depths and achieve flush alignment
Solution Approach 1:
The electrical box assembly incorporates an extendable sleeve that can be adjusted to different lengths, transforming a static fixed-depth box into a dynamic adjustable-depth system. The sleeve extends axially from the box body and can be secured at various positions using set screws, allowing the electrical box to adapt to different wall depths while maintaining structural integrity
Solution Approach 2:
The electrical box is divided into separable components: a fixed box body, an extendable sleeve, and a removable back plate. This segmentation allows the sleeve to be adjusted independently to match wall depth requirements, while the box body remains stable for mounting electrical devices
2Ease of operation
If back plate is permanently fixed, then structural integrity is maintained, but rear termination of electrical devices becomes inaccessible
Solution Approach 1:
The back plate is designed to be removably attached to the box body rather than permanently fixed. This dynamic attachment allows the back plate to be removed when rear termination is needed, providing access to electrical devices, and reattached when structural integrity and protection are required
Solution Approach 2:
The back plate can be temporarily removed during installation to allow preliminary wiring and device mounting, then reattached to provide final structural integrity and protection, embodying preliminary action for accessibility followed by final securing
3Adaptability or versatility
If electrical devices are terminated in place, then installation is straightforward, but final termination cannot occur at a different location
Solution Approach 1:
Electrical devices can be pre-installed and wired within the electrical box at a convenient location, with the back plate temporarily removed to facilitate this preliminary action. The removable back plate enables access for preliminary wiring without requiring final installation location to be the termination location, improving overall installation efficiency
Data Source
AI summary
An electrical box assembly for adjustable-depth mounting of an electrical box relative to a support structure. The electrical box assembly can include a centerplate with a centerplate opening and an electrical box with an electrical box housing, a back plate removably attached to the electrical box housing, and an extendable sleeve configured to receive fasteners of electrical devices. The electrical box can be received within the centerplate opening, with the electrical box housing secured to the centerplate. The extendable sleeve can be selectively slidable within the electrical box housing.