Electrical Box Extension with Sliding Support Flange
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Solution Overview
Problem
Existing electrical box extension solutions fail to adequately accommodate varying wall thicknesses and positions, often resulting in recessed electrical devices that are inaccessible and difficult to relocate, especially in renovation scenarios.
Innovation Solution
An adjustable electrical box extension assembly featuring a movable support flange that slides within a base without the need for adjustment screws, allowing for easy attachment to an electrical box or mounting plate and accommodating different wall thicknesses by pivoting a support flange to contact the outer wall surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing electrical box extension solutions are used, then electrical devices can be mounted to accommodate different wall thicknesses, but the electrical devices become recessed and inaccessible
Solution Approach 1:
The support flange is made movable relative to the base through a sliding mechanism guided by side walls. The flange can be positioned at different locations along the base to accommodate varying wall thicknesses, and when properly positioned, the flange presents the electrical device flush with the outer wall surface, ensuring accessibility. This dynamic adjustment resolves the contradiction between adaptability to different wall thicknesses and accessibility of the electrical device.
2Reliability
If existing electrical box extension solutions are used, then electrical devices can be mounted, but relocation and adjustment are difficult
Solution Approach 1:
The support flange is designed to slide along the base within guided side walls, allowing the electrical device to be repositioned horizontally. The coupling member provides secure attachment while the sliding mechanism enables easy adjustment and relocation. This dynamic design maintains mounting stability through the coupling member while facilitating easy repair and repositioning, resolving the contradiction between reliability and ease of repair.
3Adaptability or versatility
If adjustment screws are used in existing solutions, then positional adjustment is possible, but the device complexity increases
Solution Approach 1:
The invention extracts and eliminates the adjustment screws from the design. Instead of using threaded fasteners, the support flange utilizes a sliding mechanism along the base with guided side walls. The flange can be freely positioned and secured without requiring adjustment screws, thereby reducing device complexity while maintaining positional adjustment capability. This resolves the contradiction between adaptability and device complexity.
Data Source
AI summary
An electrical box extension includes a base, a movable ring and an extension ring. The base has an inwardly extending flange for coupling the base to the open end of an electrical box. The movable ring slides within the base and is captured by a screw that draws the movable ring into the base. The extension ring optionally can be coupled to the top end of the movable ring. A movable support flange can be coupled to the top end of either the movable ring or the extension ring for contacting the outer surface of the wall when the movable ring is drawn into the base.