Expandable Electrical Box Fixture Alignment for Rigid Assembly

Solution Overview

Problem

Existing expandable electrical boxes are difficult to assemble due to alignment issues and can be loose or misaligned, making them challenging to fit into existing wall openings.

Innovation Solution

The design incorporates coupling members or fixture members that can be easily aligned and secured to each other using fasteners, allowing for rigid and fixed assembly of modular components within the expandable electrical boxes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If expandable electrical boxes are designed with modular components, then versatility and adaptability are improved, but assembly difficulty and alignment precision deteriorate

Engineering Contradiction:

ImproveconfigurabilityVSAvoidalignment precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The fixture members are pre-formed with alignment features (such as guide pins, tapered surfaces, or pre-drilled holes) that automatically guide modular components into correct positions during assembly. This preliminary preparation of alignment features eliminates the need for complex real-time alignment procedures, resolving the contradiction between modular versatility and assembly precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Alignment features act as intermediary elements between modular components. These features (such as guide rails, positioning pins, or registration marks) mediate the connection process by providing a physical reference system that ensures precise alignment while allowing the modular components to be easily attached, thus resolving the precision-assembly contradiction.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If expandable electrical boxes are designed with modular components, then adaptability is improved, but assembly ease deteriorates

Engineering Contradiction:

ImproveconfigurabilityVSAvoidassembly ease

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The fixture members are pre-formed with alignment features (such as guide pins, tapered surfaces, or pre-drilled holes) that automatically guide modular components into correct positions during assembly. This preliminary preparation of alignment features eliminates the need for complex real-time alignment procedures, resolving the contradiction between modular versatility and assembly precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Alignment features act as intermediary elements between modular components. These features (such as guide rails, positioning pins, or registration marks) mediate the connection process by providing a physical reference system that ensures precise alignment while allowing the modular components to be easily attached, thus resolving the precision-assembly contradiction.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If traditional electrical boxes are manufactured in multiple sizes, then adaptability is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvesize varietyVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The electrical box is segmented into a standardized housing and multiple interchangeable fixture members that can be attached in different configurations. Instead of manufacturing complete boxes in various sizes, the system uses a single base housing design combined with modular fixture members, reducing manufacturing complexity while maintaining size variety and adaptability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The standardized housing design serves multiple functions across different box configurations. A single universal housing can accommodate various numbers and types of fixture members, allowing the same base component to fulfill multiple size and configuration requirements, thereby reducing the need for multiple specialized manufacturing processes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20250192528A1Expandable electrical box

Publication Date: 2025.06.12 ONEBOXFORALL LLC

AI summary

An expandable electrical box can comprise a housing comprising a rear wall, a top wall, a bottom wall and a fixed side wall defining an interior space, an open side opposite the fixed side wall, wherein a front of the housing is open, and a first fixture member connected to the housing, and a removable side wall configured to releasably cover the open side of the housing, the removable side wall comprising a second fixture member connected to the removable side wall, wherein the first fixture member and the second fixture member are aligned to receive a fastener therethrough.