Interlocking Electrical Box Extender for Multi-Gang Configurations
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Solution Overview
Problem
Existing electrical box installations often become recessed too far from newly finished wall surfaces during renovations, requiring box extenders to maintain proper depth, and existing solutions do not easily accommodate multi-gang configurations without additional tools or modifications.
Innovation Solution
The design of interlocking electrical box extenders that can be joined side-by-side without modification to form multi-gang configurations, using male and female flanges to maintain spacing and secure within standard electrical boxes, allowing for easy expansion from single-gang to multi-gang installations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single-gang electrical box extender is used, then the electrical box depth is extended to meet wall surface requirements, but the configuration cannot accommodate multiple electrical components without additional tools or modifications
Solution Approach 1:
The electrical box extender is divided into modular sections with standardized interlocking flanges, allowing multiple single-gang extenders to be joined together to form multi-gang configurations. This segmentation enables the system to adapt to different gang requirements using the same basic component design.
Solution Approach 2:
The extender design incorporates universal interlocking flanges that can join any extender to any other extender regardless of position or orientation. This multi-functionality allows a single extender design to serve both as a standalone single-gang solution and as a building block for multi-gang installations, eliminating the need for different extender types.
2Adaptability or versatility
If multiple different extender types are used to accommodate various gang sizes, then specific gang configurations can be achieved, but inventory complexity and supply chain management become more difficult
Solution Approach 1:
By designing extenders with standardized universal flanges, the system allows a single stock-keeping unit to fulfill multiple gang configuration needs. Electricians can create double-gang, triple-gang, or quadruple-gang installations by joining multiple identical single-gang extenders, dramatically reducing the number of different extender types that need to be inventoried and managed.
Solution Approach 2:
The modular segmented design allows the system to create various gang sizes through combinatorial assembly of standard units, similar to how LEGO bricks can create different structures from the same set of pieces. This approach reduces inventory requirements from needing separate extenders for each gang size to只需要 a single extender design.
3Ease of operation
If traditional electrical box installations are used, then installation is simple for standard depths, but the boxes become recessed too far from newly finished wall surfaces during renovations
Solution Approach 1:
The extender is designed to be pre-formed with the correct depth extension and interlocking flanges, allowing electricians to simply attach it to the existing electrical box without complex modifications. The preliminary preparation of the extender components enables quick installation that maintains proper box depth relative to the finished wall surface.
Data Source
AI summary
An electrical box extender includes a rectangular tube having a first pair of opposing sides and a second pair of opposing sides. The first pair of opposing sides and the second pair of opposing sides form a perimeter configured to fit within a single-gang electrical box. The electrical box extender also includes a set of flanges extending laterally from a front edge of the first pair of opposing sides. The set of flanges includes a male interlocking flange and a female interlocking flange. The male interlocking flange is configured to attach to another female interlocking flange of a substantially identical electrical box extender.