Pull-out Extension for Electrical Box Depth Adjustment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical outlet boxes often require additional labor and time to adapt to varying wall finishes, as the offset for flush installation with finishing materials like ceramic or stone tile is insufficient, necessitating separate extensions or longer screws.
Innovation Solution
A pull-out extension device for electrical outlet boxes featuring a resilient tab that can be inserted and adjusted within the box to increase depth, allowing for flush installation with different thicknesses of finishing materials without additional attachments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If standard outlet boxes are used with fixed depth, then the box structure is simple and easy to manufacture, but the box cannot be adjusted to accommodate different thicknesses of finishing materials like ceramic or stone tile
Solution Approach 1:
The outlet box is divided into two separate components: a standard fixed-depth box and an adjustable extension. The extension can be added when needed to accommodate thicker finishing materials, while the basic box remains simple for standard applications. This segmentation allows the system to adapt to different conditions without increasing the complexity of the fundamental box design.
Solution Approach 2:
The extension incorporates resilient tabs that can be compressed and released to adjust the extension depth dynamically. This dynamic mechanism allows the installer to extend the box to different depths depending on the finishing material thickness, providing adaptability while maintaining a relatively simple overall structure.
2Ease of operation
If extensions are added to bridge the gap between box opening and finish material surface, then flush installation with various wall finishes is achieved, but additional labor and time are required for installation
Solution Approach 1:
The extension is pre-formed with resilient tabs designed to snap into place on the box. This preliminary preparation of the extension component allows for quick installation by simply compressing the tabs and attaching the extension to the box, significantly reducing the time and labor required compared to fabricating or complexly assembling extension solutions on-site.
Solution Approach 2:
The resilient tabs provide a dynamic, tool-free attachment mechanism that allows the extension to be quickly installed and adjusted. The compression and release action of the tabs enables rapid securing of the extension to the box, minimizing installation time while ensuring secure attachment for flush installation with various wall finishes.
3Adaptability or versatility
If longer screws are used to install electrical devices, then flush installation with thicker finishes is achieved, but the screw length is fixed and cannot be adjusted for different finish thicknesses
Solution Approach 1:
Instead of using a single fixed-length screw solution, the system segments the depth adjustment function into a separate extension component. The extension provides the additional depth needed for thicker finishes, while the electrical device mounting remains separate. This allows the mounting screws to remain standard length while the extension bridges the depth gap, avoiding the need for variable-length screws or complex adjustable mounting mechanisms.
Solution Approach 2:
The extension acts as an intermediary component between the fixed-depth box and the electrical device mounting surface. It provides the additional depth required for thicker finishing materials while maintaining a standard mounting interface for the electrical device. This intermediary solution avoids the need for adjustable screw lengths or complex mounting mechanisms, keeping the installation method simple.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables easy and efficient flush installation with various wall finishes, reducing labor and ensuring compliance with electrical codes by allowing adjustable extension of the box depth post-finishing material installation.
Implementation Method 1
at least one outwardly protruding resilient tab located on the side wall outer surface
Data Source
AI summary
An electrical outlet box extension comprising a perimetrical side wall with an inner surface and an outer surface having an open front face and an open rear face and defining an interior space, and having at least one outwardly protruding resilient tab located on the side wall outer surface. The box extension is designed for adjustable insertable receipt within an electrical outlet box for increasing the depth of the box.