Flush Floor Box With Integrated Leveling And Grounding
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Solution Overview
Problem
Current flush floor boxes are expensive to manufacture and difficult to install and level, as they require complex assembly and lack efficient grounding mechanisms.
Innovation Solution
A flush floor box design featuring a base with integral leveling screws and a leveling ring with grounding tabs, where the leveling ring is fastened to the base using screws that also provide electrical connections, and a cover with a power outlet, utilizing sealing layers and fasteners for secure and grounded installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional floor box designs are used, then grounding and leveling functions are provided, but manufacturing cost is high and installation complexity is high
Solution Approach 1:
The patent combines multiple functions into integrated components: the leveling ring integrates both leveling adjustment and grounding functions, while the cover integrates power outlet mounting and sealing functions. This consolidation reduces the number of separate parts and simplifies assembly, directly addressing the contradiction between providing comprehensive functions and reducing manufacturing/installation complexity.
Solution Approach 2:
The fasteners serve dual purposes: mechanically securing the leveling ring to the base while simultaneously providing electrical connection paths for grounding. This multi-functionality eliminates the need for separate grounding components, reducing part count and simplifying both manufacturing and installation processes.
2Reliability
If multiple separate components are used for grounding and leveling, then functional requirements are met, but device complexity increases
Solution Approach 1:
The fasteners are designed to simultaneously perform mechanical fastening and electrical connection functions. By using these multi-functional fasteners, the patent maintains reliable electrical bonding between components while reducing the total number of parts needed, thus resolving the contradiction between reliability and device complexity.
Solution Approach 2:
The grounding path is integrated into the mechanical assembly structure itself, where the fasteners create both structural and electrical connections. This merging of structural and electrical functions into a single integrated system maintains bonding reliability while minimizing the number of discrete components.
3Strength
If traditional assembly methods are used, then components are secured, but installation time increases
Solution Approach 1:
The integration of multiple functions into fewer components (leveling ring combining leveling and grounding, cover combining mounting and sealing) naturally reduces the number of assembly steps. The fasteners simultaneously accomplish both mechanical securing and electrical connection in a single operation, reducing installation time while maintaining assembly strength.
Data Source
AI summary
The present disclosure relates to a flush floor box that can be constructed at a lower cost and is easier to install than previously utilized flush floor boxes. The flush floor box includes a base and/or a leveling ring with integral features. The integral features help to reduce the cost of producing the flush floor box. The leveling ring can include ears/tabs for use in electrically grounding a top shield of a flat floor power cable.