Recessed Electrical Box Frame for Impact Protection
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Solution Overview
Problem
Conventional exterior electrical boxes are prone to damage from hazards due to their outward-extending covers, which expose them to contact with lawnmowers, vehicles, and other objects.
Innovation Solution
An electrical box assembly comprising a frame member with a peripheral flange and inward-sloping sidewalls that recesses the outlet box and its cover flush or within the wall surface, providing protection from accidental contact and enhancing stucco adhesion in stucco versions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional exterior electrical boxes are installed flush with the wall surface, then the electrical box and cover extend outward from the wall, but they become prone to damage from lawnmowers, vehicles, and other hazards
Solution Approach 1:
The frame member extends the electrical box assembly into the third dimension by protruding from the wall surface. The frame includes a front face that extends forward from the wall, creating a recessed cavity that houses the electrical box. This dimensional extension allows the electrical box to be protected within the frame structure while maintaining flush or recessed positioning relative to the outer wall surface.
2Reliability
If the electrical box cover extends outward from the wall surface to cover the electrical device, then the device is protected, but the cover becomes exposed to accidental contact by lawn equipment and vehicles
Solution Approach 1:
The electrical box is nested within the frame member structure. The frame member acts as an outer enclosure that contains the electrical box assembly. The frame's recessed cavity houses the electrical box, and the entire assembly is positioned within or flush with the outer wall surface, creating a nested configuration that protects the electrical device while maintaining coverage.
3Reliability
If the frame member recesses the electrical box substantially from the front edge, then the outlet box assembly becomes flush with or recessed within the wall surface, but the frame member structure becomes more complex
Solution Approach 1:
The frame member performs multiple functions simultaneously: it provides structural support for the electrical box, creates the recessed cavity for housing the device, extends forward to establish the outer wall surface alignment, and offers protection against impacts. This multi-functionality reduces the need for additional separate components, thereby managing complexity while achieving comprehensive protection.
Data Source
AI summary
An electrical box assembly including a frame member and an outlet box assembly with an outlet box and a hinged cover. The frame member includes a peripheral flange and inward sloping sidewalls that extend to a rear panel having a central opening therein. The outlet box includes a flange and a rearward extending sidewall portion. The frame member can be secured to a wall and the rearward extending sidewall of the outlet box inserted into the central opening of the frame member until the flange of the outlet box seats against the rear panel of the frame member. The rear panel of the frame member is recessed a substantial distance from the front edge of the frame member, thereby ensuring that the outlet box assembly and hinged cover in a closed configuration will be recessed within the outer surface of the wall.