Non-Metallic Electrical Floor Box Flush Mounting Design
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Solution Overview
Problem
Existing electrical outlet boxes for floors are difficult to install in pre-existing, finished floors without damaging the surface or leaving a neat, secure installation.
Innovation Solution
A non-metallic floor electrical box design comprising a box portion with a mounting flange that sits flush against the floor, a backplate for securing the electrical outlet, and a cover plate that seals the top, allowing for easy installation and secure mounting within a pre-cut hole in the floor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional electrical outlet box is installed in a pre-existing finished floor, then the electrical outlet can be mounted, but the floor surface is damaged or the installation is not neat and secure
Solution Approach 1:
The outlet box is divided into separate components: a box portion for housing the electrical outlet, a mounting flange for attachment to the floor, a backplate for securing the outlet, and a cover plate for sealing. This segmentation allows each component to perform its specific function while minimizing damage to the finished floor surface during installation
Solution Approach 2:
The mounting flange is designed with pre-defined attachment holes and a structure that sits flush against the floor surface, allowing for preliminary positioning and secure attachment before the cover plate is installed. This preliminary action ensures the outlet box is firmly mounted without requiring damage to the finished floor
2Ease of operation
If a traditional electrical outlet box is installed in a pre-existing finished floor, then the electrical outlet can be mounted, but the installation is not neat
Solution Approach 1:
The mounting flange integrates multiple functions into a single component: it provides the mounting surface for the box portion, contains attachment holes for secure fastening, and extends beyond the box to provide a flush mounting surface against the floor. This merging simplifies the installation process while achieving a neat appearance
Solution Approach 2:
The backplate is inserted into the box portion and secures the electrical outlet within the cavity. The cover plate then mounts to the box portion and closes off the open top end. This nested arrangement of components creates a compact, neat installation that fits within the floor opening without protruding
3Ease of operation
If the cover plate is positioned to cover the mounting flange, then a neat appearance is achieved, but the attachment holes may fall outside the floor perimeter
Solution Approach 1:
The mounting flange is designed with attachment holes positioned at specific locations that are optimized for both aesthetic appearance and practical mounting. The local quality of the flange structure provides reinforcement and mounting capability at the periphery while maintaining a neat appearance when the cover plate is installed
Data Source
AI summary
An electrical outlet box for installing in a hole defined in a pre-existing, finished floor of a building. The outlet box comprises a box portion, a backplate, and a cover plate. The box portion comprises a first pair of opposing walls, a second pair of opposing walls, a bottom wall, and a mounting flange. Top edges of each wall of the first and second pairs of opposing walls define an open top end of the box portion. The bottom wall is affixed to bottom edges of each wall of the first and second pairs of opposing walls, thereby defining a cavity within the first and second pairs of opposing walls and the bottom wall. The cavity is adapted for receiving an electrical outlet. The mounting flange surrounds the open top end and is adapted for sitting flush against the installed floor when the outlet box is mounted in the hole.