Integrated Electrical Fitting with Integral Cover Plate

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Solution Overview

Problem

The existing electrical fitting installation process is labor-intensive and costly, requiring three steps to replace or upgrade fittings, with separate cover plates and fittings needing different fastener locations and more openings, leading to increased inventory and labor costs.

Innovation Solution

A composite electrical fitting with an integrally formed cover plate, where the fitting and cover plate are secured via screws through the cover plate into the wall box, using quick-connect members to secure wires and reduce the number of fasteners required.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate cover plates and fittings are used with different fastener locations, then the installation requires more openings in the wall box, but this increases device complexity and inventory requirements

Engineering Contradiction:

Improveinstallation flexibilityVSAvoidnumber of openings required

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines the cover plate and electrical fitting into a single integrated unit with a unified backbox engagement structure. This merging eliminates the need for separate fastener locations and multiple openings, reducing device complexity while maintaining installation flexibility through the integrated design

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If a three-step installation process is used for separate fittings and cover plates, then comprehensive coverage is achieved, but this increases loss of time and labor costs

Engineering Contradiction:

Improveinstallation completenessVSAvoidinstallation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

By integrating the cover plate and fitting into one unit, the patent reduces the installation process from three separate steps to a single step, significantly reducing installation time while maintaining complete electrical and mechanical connection reliability through the integrated design

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cover plate is pre-integrated with the fitting in a single manufactured unit, so that during installation, the entire assembly is ready to be engaged with the backbox in one action, eliminating the need for sequential installation steps and reducing overall installation time

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If separate fittings and cover plates are stocked as individual SKUs, then product variety is maintained, but this increases loss of substance through inventory record-keeping costs

Engineering Contradiction:

Improveproduct varietyVSAvoidinventory management costs

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The patent merges the cover plate and fitting into a single integrated product unit, which reduces inventory complexity by eliminating the need to track separate SKUs for cover plates and fittings, thereby reducing inventory management costs while still offering product variety through different integrated unit configurations

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS9178344B2Electrical fittings with integral cover plate and method of use thereof

Publication Date: 2015.11.03 MOSS J

AI summary

An electrical fitting that comprises an integral cover plate and an electrical component, such as an outlet or a switch, the combined electrical component/cover plate being secured via screws through the cover plate into a wall box. Wires are secured to power wires coming from the wall box via quick-connectors or wirenuts.