Outlet Box Frame with Unitary Screw Guide for Floor Anchoring
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Solution Overview
Problem
Contemporary poke-through floor boxes are difficult to remove or reposition once installed, and their self-anchoring designs often damage the assembly and incur additional manufacturing costs due to custom-made retaining rings.
Innovation Solution
An outlet box frame assembly with a unitary retaining screw guide that engages the floor's internal wall without significant penetration, providing resistance against pullout and rotation, and allowing for easy adjustment and repositioning, while using a screw anchor that is less expensive than traditional retaining rings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a retaining ring is used to anchor the floor box, then the anchoring strength is improved, but the ease of removal and repositioning deteriorates
Solution Approach 1:
The anchoring system is divided into separate components: the frame with integrated screw guides and removable anchor screws. This segmentation allows the anchoring function to be maintained while enabling easy removal and repositioning, as the screws can be independently removed without damaging the frame or floor structure.
Solution Approach 2:
The anchoring system transitions from a static, permanent retaining ring to a dynamic, adjustable screw-based system. The screw guides provide stable positioning during installation, while the removable screws allow for easy adjustment and repositioning, making the system adaptable to different installation scenarios.
2Reliability
If a custom retaining ring is used for self-anchoring, then the anchoring reliability is improved, but the manufacturing cost increases
Solution Approach 1:
The screw guides are integrated directly into the frame as a unitary structure, combining the framing and anchoring guidance functions into a single component. This eliminates the need for separate custom retaining rings, reducing manufacturing complexity and cost while maintaining anchoring reliability through the standardized screw-guide-screw anchor system.
Solution Approach 2:
The unitary screw guide structure serves multiple functions: it provides structural support as part of the frame, guides the anchor screws during installation, and ensures proper positioning without requiring custom manufacturing. This multi-functionality reduces the need for specialized components and lowers overall manufacturing costs.
3Strength
If a retaining ring is used to secure the floor box, then the resistance to pullout and rotation is improved, but the complexity of the assembly increases
Solution Approach 1:
The anchoring function is segmented into the frame with integrated guides and separate screw anchors. This simplifies the overall assembly by eliminating the complex retaining ring structure while maintaining the necessary resistance to pullout and rotation through the screw-guide interface.
Solution Approach 2:
The screw guides are merged with the frame structure, eliminating the need for separate retaining ring components. This integration reduces assembly complexity by reducing the number of parts while maintaining anchoring strength through the direct connection between screws, guides, and frame.
Data Source
AI summary
One aspect of the invention is an outlet box frame for installation in a hole in a floor structure. The hole having a perimeter and defining an internal wall surface in said floor structure. The frame including a walled member, at least one flange portion and a unitary retaining screw guide. The walled member being sized for insertion within the hole. The at least one flange portion extending outward from the walled member, wherein once installed at least a portion of the flange extends from the walled member past the internal wall surface. The unitary retaining screw guide supports a retaining screw. The screw guide being supported from the walled member and configured to receive the retaining screw therein. Upon installation, the retaining screw inserted in the retaining screw guide engages the hole wall without significant penetration thereof, providing at least pullout resistance of the frame from the hole. Alternatively, the outlet box frame may include the retaining screw.