Flush Electrical Box with Integrated Cover and Flange
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Solution Overview
Problem
Current electrical outlet designs fail to penetrate the market due to issues with safety, aesthetics, cost, and ease of installation, as they are either too obtrusive, costly, or difficult to install, and lack a combination of aesthetically appealing, user-friendly, and cost-effective features that allow for easy access and energy savings.
Innovation Solution
A multi-configured electrical box with integrated flange and cover mechanisms that can be mounted in recessed or un-recessed positions, featuring low-profile designs, hidden closure mechanisms, and seamless integration with drywall, allowing for easy access and energy savings by sealing gaps between the electrical box and drywall.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If safety features are added to electrical outlets to protect children, then child safety is improved, but the design becomes more obtrusive and installation becomes more difficult
Solution Approach 1:
The patent implements a nested cover system where a secondary safety cover is housed within the primary decorative cover. The secondary cover can be independently accessed and removed to reach the outlet, while the primary cover remains in place to maintain aesthetic appearance and provide additional protection. This nesting approach adds safety functionality without requiring complete redesign of the outlet assembly.
Solution Approach 2:
The cover assembly is divided into multiple independent segments: an outer decorative cover and an inner safety cover. Each cover can be independently installed, removed, or adjusted. This segmentation allows the safety function to be added or removed without affecting the decorative appearance, and enables flexible installation approaches for different applications.
2Shape
If recessed outlet design is implemented to improve aesthetics, then wall appearance is improved, but compatibility with low voltage devices is reduced
Solution Approach 1:
The patent provides a dynamic configuration system where the outlet box can be installed at different depths (recessed or surface-mounted) and the cover can be adjusted between closed and open positions. This dynamic adaptability allows the same basic design to accommodate both aesthetic requirements for recessed installation and functional requirements for low voltage devices that may need protruding positioning.
Solution Approach 2:
The outlet assembly is designed with universal compatibility features including adjustable mounting brackets, multiple cover configurations, and standardized electrical connections that work with both high voltage and low voltage devices. The modular design allows the same base unit to serve multiple functions across different application scenarios.
3Ease of manufacture
If standard electrical outlets are used to ensure ease of installation, then installation simplicity is maintained, but aesthetic appeal and energy efficiency are reduced
Solution Approach 1:
The patent merges multiple functions into a single integrated assembly: the electrical outlet, decorative cover, safety cover, and mounting mechanism are combined into one pre-assembled unit. This allows installers to install the entire assembly as a single component, maintaining the simplicity of standard outlet installation while incorporating aesthetic and safety features that would otherwise require separate installation steps.
Solution Approach 2:
The cover assembly and safety mechanisms are pre-configured and pre-assembled during manufacturing before installation. The mounting brackets, covers, and electrical connections are prepared in advance, allowing the installer to simply mount the complete assembly to the wall without requiring complex assembly steps on-site.
4Object-affected harmful factors
If detachable covers are used to provide safety and aesthetics, then outlet protection is improved, but user access becomes more difficult and requires storage space
Solution Approach 1:
The patent extracts the safety function from a removable cover and implements it through a secondary cover that is hinged to the outlet assembly. This secondary cover can be swung open or detached as needed, while the primary decorative cover remains permanently attached to maintain both protection and aesthetic appearance. The hinged design eliminates the need to completely remove covers for access.
5Object-affected harmful factors
If multiple safety mechanisms are added to electrical outlets, then child safety is improved, but manufacturing cost increases
Solution Approach 1:
The patent uses thin, lightweight plastic materials for both the decorative cover and safety cover. These thin-walled components are cost-effective to manufacture through injection molding and can be produced in high volumes. The flexible nature of these thin-shell covers allows for complex shapes and integrated features without significantly increasing material costs or manufacturing complexity.
Data Source
AI summary
A “no profile” electrical box, integrated flange/protective assembly and interchangeable cover that obscures standard electrical outlets such that a wall surface appears nearly continuous, uninterrupted by the outlet or cover when in use or not in use. The profile of the combined unit equals only the thickness of the material from which it is constructed; no hinges, screws or fasteners of any kind are visible and no part of the assembly requires detachment or storage when the outlet is in use, as the hinged cover is undetectably stored in the electrical box, or may be used to cover the electrical cords when engaged in the outlet. Exemplary embodiments of the cover obscure the electrical outlet. Together, the electrical box and flange assembly allow the electrical outlet to be flush mounted or recessed interchangeably, even after installation.