Flush-Mounted Electrical Box Assembly for Concrete Walls
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Solution Overview
Problem
Conventional electrical outlet boxes in concrete walls require visible cover plates, which are both aesthetically unpleasing and violate the refined appearance sought in high-end construction, while also posing a challenge in complying with building codes.
Innovation Solution
A method and apparatus for installing electrical outlets or switches directly into a concrete wall without a visible cover plate, using a junction box assembly with a secondary plate and removable blank that allows for flush mounting, ensuring compliance with building codes and providing a seamless finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional outlet boxes with cover plates are used in concrete walls, then structural support and safety functions are ensured, but aesthetic appearance deteriorates due to visible cover plates
Solution Approach 1:
The invention extracts and removes the cover plate component from the outlet box assembly, eliminating the visual distraction while preserving the essential structural functions through alternative mounting methods that integrate the box directly into the concrete wall surface
Solution Approach 2:
The invention transitions from a protruding outlet box configuration to a flush-mounted configuration by changing the dimensional relationship between the outlet box and wall surface, achieving both aesthetic improvement and structural integrity through proper embedment depth control
2Shape
If outlet boxes are mounted flush in concrete walls without cover plates, then aesthetic appearance improves, but installation complexity increases due to code compliance requirements
Solution Approach 1:
The invention incorporates preliminary action by pre-planning the embedment depth and positioning of the outlet box during the concrete pouring process, and by pre-assembling the box within the formwork before concrete placement, thereby simplifying the overall installation while achieving flush mounting compliance with building codes
3Shape
If outlet boxes are mounted flush in concrete walls, then aesthetic appearance improves, but installation time increases due to additional preparation steps
Solution Approach 1:
The invention merges the outlet box installation with the concrete wall construction process itself, integrating the box mounting into the formwork assembly and concrete pouring operations, thereby achieving flush mounting aesthetic results without adding separate installation steps that would increase time consumption
Data Source
AI summary
Systems for mounting an electrical junction box in a concrete structure and methods of making concrete structures with such electrical junction boxes molded therein are disclosed. The system includes a secondary plate configured to be mounted to a closure plate of an electrical junction box, a removable blank seated in the second through hole, and a bolt extending through the removable blank. The removable blank protrudes forward a distance sufficient to mount to a concrete form. The secondary plate has a forward protruding flange defining a second through hole aligned with the first through hole and a rear surface of the secondary plate comprises a recess therein that extends from the second through hole in a radial outward direction and the bolt terminates with a foot and the recess of the secondary plate is shaped to receive the foot to define a latched position for the removable blank.