Gangable Electrical Box Leveling Assembly
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Solution Overview
Problem
Existing gangable electrical boxes face challenges in accommodating varying wall thicknesses and angles, leading to recessed electrical devices that are difficult to access and adjust, especially in new or renovated constructions.
Innovation Solution
A gangable electrical box with interlocking tabs for coupling multiple units and adjustable leveling members at each end, allowing independent adjustment of the electrical device's position and angle relative to the wall and the box, along with a removable divider plate for post-installation insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If electrical boxes are mounted using traditional fixed mounting methods, then the installation process is simple and quick, but the electrical devices end up recessed within the wall and are difficult to access
Solution Approach 1:
The patent applies the dynamics principle by providing an adjustable mounting assembly that allows the electrical box to be positioned at variable distances from the wall surface. The mounting assembly includes adjustment mechanisms that enable dynamic repositioning of the electrical box, transforming it from a fixed to an adjustable system. This resolves the contradiction by allowing the electrical device to be positioned optimally for accessibility while maintaining a relatively simple mounting structure through standardized components.
Solution Approach 2:
The mounting assembly is segmented into multiple independent components including the mounting plate, adjustment mechanism, and electrical box mounting structure. This segmentation allows each component to be optimized independently and facilitates easy installation and adjustment. The modular design resolves the contradiction by breaking down the complex mounting task into manageable segments that collectively achieve improved accessibility without proportionally increasing overall complexity.
2Adaptability or versatility
If electrical boxes are mounted to accommodate varying wall thicknesses and angles, then accessibility is improved, but the mounting structure becomes more complex
Solution Approach 1:
The mounting assembly incorporates dynamic adjustment capabilities that allow it to adapt to varying wall thicknesses and angles. The adjustment mechanism includes movable components that can be positioned to compensate for different wall conditions, providing versatility without requiring completely different mounting structures for each scenario. This resolves the contradiction by enabling a single mounting structure to handle multiple wall conditions through adjustment rather than through inherent complexity.
Solution Approach 2:
The mounting assembly allows for changes in mounting parameters such as distance from wall surface, angle of mounting, and position of the electrical box. These parameter changes are achieved through adjustment mechanisms that modify the geometric parameters of the mounting structure. This resolves the contradiction by providing adaptability to varying wall conditions through controlled parameter changes rather than through complex structural design.
3Adaptability or versatility
If adjustable mounting mechanisms are added to electrical boxes, then positioning flexibility is improved, but the installation and adjustment process becomes more complex
Solution Approach 1:
The adjustable mounting mechanism is segmented into standardized, pre-fabricated components that can be manufactured independently and assembled during installation. This segmentation allows each component to be optimized for ease of manufacture while collectively providing positioning flexibility. The modular design resolves the contradiction by enabling positioning flexibility through simple assembly of standardized parts rather than through complex custom manufacturing.
Solution Approach 2:
The mounting assembly incorporates self-adjusting features that allow installers to easily modify the position and orientation of the electrical box without requiring complex tools or procedures. The adjustment mechanisms are designed to be user-friendly, with features such as adjustable brackets and repositionable mounting plates that enable easy modification. This resolves the contradiction by providing positioning flexibility through self-service adjustment capabilities rather than through complex installation procedures.
Data Source
AI summary
A gangable electrical box includes an adjustment assembly for adjusting the position and angle of an electrical device mounted in the box. The adjustment assembly includes independently adjustable leveling members coupled to opposite end walls of the box. A side member is slidably coupled to a side wall and extends between the end walls. The side wall engages the leveling members and is adjustable with the adjustment of the leveling members.