Junction Box Cover Plate With Hidden Screw Interlock Assembly
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Solution Overview
Problem
Electrical junction boxes are often left exposed when not in use, appearing unsightly and lacking a clean, screwless aesthetic.
Innovation Solution
A screwless look junction box cover plate assembly is designed, comprising a cover plate with an annular lip and entry ports, and a cover attachment bar with extensions that interlock with the annular lip, allowing the cover plate to rotate and conceal the junction box, attachment bar, and screws.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional cover plates with visible screws are used, then the junction box is concealed and secured, but the aesthetic appearance is compromised due to visible screws and mounting hardware
Solution Approach 1:
The cover plate is divided into multiple components: a main cover plate, a separate attachment bar, and extensions that fit into entry ports. This segmentation allows the mounting hardware to be hidden while maintaining structural integrity and aesthetic appearance.
Solution Approach 2:
The attachment bar serves as an intermediary element between the cover plate and the junction box. It provides mounting surfaces for screws while being concealed by the cover plate, thus mediating between the need for secure attachment and the desire for clean aesthetics.
2Shape
If the cover plate conceals all mounting hardware, then the aesthetic appearance is improved, but the ease of installation and maintenance is reduced
Solution Approach 1:
By segmenting the cover plate into removable components (cover plate, attachment bar, extensions), the design allows for easy assembly and disassembly. The extensions can be inserted into entry ports from the front, eliminating the need to work from behind the plate.
Solution Approach 2:
Instead of requiring screws to be accessed from behind the cover plate, the design inverts the approach by providing entry ports through which extensions can be inserted from the front, making installation and maintenance easier while maintaining aesthetic appearance.
3Ease of manufacture
If a simple cover plate design is used, then the manufacturing cost is reduced, but the ability to conceal mounting hardware is compromised
Solution Approach 1:
The segmented design allows each component to be manufactured separately using simple processes, then assembled together to achieve the aesthetic effect. This avoids the need for complex single-piece manufacturing while maintaining visual appeal.
Solution Approach 2:
The attachment bar serves multiple functions: it provides structural support, conceals screws, and facilitates installation through the extensions and entry ports. This multi-functionality reduces the need for additional components, simplifying manufacturing while achieving aesthetic goals.
Data Source
AI summary
An electrical junction box cover plate assembly with an electrical junction box and a cover attachment bar. Each end of the cover attachment bar has an attachment screw aperture that aligns with a mounting screw aperture of the electrical junction box. A cover plate has an upper side with a cavity, an annular lip extending inward into the cavity, and at least two entry ports extending through the annular lip, each configured to receive one of the two ends of the cover attachment bar. When the ends of the cover attachment bar are inserted into the entry ports, the cover plate is rotatable with respect to the cover attachment bar and the electrical junction box to interlock extensions of the two ends with the annular lip of the cover plate to conceal the electrical junction box, the cover attachment bar, and the screws.