Electrical Box Assembly Leveling Ring Concrete Pour Alignment
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Solution Overview
Problem
Existing electrical boxes for concrete pours often shift during the concrete curing process, requiring cumbersome clip or adhesive-based leveling solutions, which are difficult to implement and adjust, and do not accommodate both high and low voltage components.
Innovation Solution
An electrical box assembly with integrated mounting bosses and a leveling ring featuring a flange that overlaps the box rim, eliminating the need for clips and adhesive, and allowing for easy adjustment and mounting of various electrical components and covers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If clips or adhesive are used to secure the leveling ring to the electrical box, then the leveling ring can be mounted to the box, but the installation process becomes cumbersome and difficult to adjust
Solution Approach 1:
The mounting system is divided into separate components: mounting bosses integrated into the electrical box and corresponding mounting tabs on the leveling ring. This segmentation allows for easy assembly by simply snapping the tabs onto the bosses without requiring clips or adhesive, eliminating installation complexity while maintaining secure mounting.
Solution Approach 2:
Mounting bosses serve as intermediary elements between the electrical box and the leveling ring. These bosses provide a standardized interface that simplifies the connection process, allowing the leveling ring to be securely mounted through a simple snap-fit mechanism rather than requiring complex clip or adhesive applications.
2Adaptability or versatility
If the electrical box is placed within the form area for concrete pour, then electrical outlets can be installed in the concrete floor, but the concrete pour forces the electrical box out of alignment with the concrete surface
Solution Approach 1:
The electrical box design incorporates a removable top portion and adjustable mounting system that allows the box to be dynamically repositioned and realigned after the concrete pour. This dynamic capability enables the installer to cut the box to the proper height and adjust the leveling ring to achieve precise alignment with the concrete surface, even when the box shifts during pouring.
Solution Approach 2:
The mounting bosses can be cut to different lengths to accommodate varying concrete pour depths and slopes. By changing the parameter of the mounting boss length, the electrical box can be repositioned to maintain proper alignment with the finished concrete surface regardless of pour variations.
3Manufacturing precision
If the top portion of the electrical box is cut to align with the concrete surface, then alignment with the concrete surface is achieved, but the mounting mechanism must remain secure
Solution Approach 1:
The electrical box is segmented into a removable top portion and a base portion with integrated mounting bosses. This segmentation allows the top to be cut to the proper height for alignment while the base with the mounting bosses remains intact, maintaining the secure mounting connection to the leveling ring.
Solution Approach 2:
The mounting bosses are pre-integrated into the electrical box base during manufacturing, positioned to ensure secure mounting even after the top portion is cut. This preliminary integration of the mounting mechanism ensures that cutting the box for alignment does not compromise the security of the mounting connection.
Data Source
AI summary
An electrical box assembly for concrete pours. The electrical box assembly includes an electrical box with a sidewall defining an electrical enclosure and a leveling ring for accepting the mounting of an electrical component to the box. Mounting bosses within the electrical box extend longitudinally along the inner surface of the sidewall and facilitate a means for mounting the leveling ring to the electrical box. The leveling ring includes a flange that is adapted to overlap the top rim of the electrical box. Component attachment arms on the leveling ring enable mounting of an electrical component to the electrical box assembly. Cover attachment arms on the leveling ring facilitate mounting of an electrical cover to the electrical box assembly. The electrical box assembly eliminates the need for clips and adhesive for leveling an electrical component with respect to the surface of a concrete poured surface.