Pivotable Mud Ring Insert for Flush Electrical Device Mounting
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Solution Overview
Problem
Existing mud rings for electrical devices lack adjustable and secure mounting solutions, making it difficult to position electrical devices flush with walls and ceilings, and they do not provide easy access for installation and maintenance.
Innovation Solution
A mud ring system comprising a base member, a cover, and an insert, with a latch and actuator mechanism that allows for pivoting and adjustable positioning of the insert relative to the cover, enabling secure attachment to junction boxes with various configurations and easy access for installation and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional fixed mud ring is used, then the structure is simple, but the electrical device cannot be adjusted to achieve flush mounting with walls and ceilings
Solution Approach 1:
The mud ring incorporates a pivotable cover and an insert that can move relative to the cover, transforming the fixed structure into a dynamic one. This allows the electrical device to be adjusted to different positions and angles, enabling flush mounting with walls and ceilings while maintaining a relatively simple overall structure.
Solution Approach 2:
The mud ring is divided into multiple functional segments: a base member, a pivotable cover, and a movable insert. This segmentation allows each component to perform specific functions independently, providing adjustment capability without significantly increasing overall structural complexity.
2Ease of operation
If the cover is secured to the base member, then the structure is stable, but access to the interior portion of the junction box is blocked
Solution Approach 1:
The cover is designed to be pivotable relative to the base member, allowing it to move between a closed position (providing stability) and an open position (providing access). This dynamic design resolves the contradiction by enabling both stable mounting and easy access to the junction box interior.
Solution Approach 2:
The separation of the cover from the base member, connected through a pivot mechanism, allows independent movement of the cover. This segmentation enables the cover to be opened for access while the base member remains securely mounted to the junction box.
3Adaptability or versatility
If the insert is fixed in the cover, then the structure is simple, but the electrical device cannot be positioned at different locations
Solution Approach 1:
The insert is designed to move relative to the cover along a path, transforming the fixed positioning into an adjustable one. This allows the electrical device to be positioned at different locations within the cover while maintaining a relatively simple overall structure through the use of guided movement mechanisms.
4Reliability
If multiple fasteners are used to secure the base member, then the mounting is secure, but the installation time increases
Solution Approach 1:
The base member is designed with a profile that extends around fastener mounting portions of the junction box, allowing multiple fasteners to be positioned strategically. This segmentation of the fastening points enables secure mounting while potentially reducing the total number of fasteners needed compared to a fully enclosed design.
Data Source
AI summary
A mud ring supports an electrical device with respect to a junction box. The mud ring includes a base member configured to be coupled to the junction box; a cover coupled to the base member for movement between a first position and a second position, the cover including an opening; and an insert positioned in the opening and supported for movement relative to the cover, the insert configured to be coupled to the electrical device.