Sliding Electrical Box for Concrete Wall Forms
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Solution Overview
Problem
Existing electrical outlet boxes are not well-suited for concrete walls, lacking features for secure attachment to forms during concrete pouring, leading to potential displacement or infiltration of concrete, and require additional work to extend the box after pouring.
Innovation Solution
An electrical outlet box with a slidable extension and nail attachment system that securely fastens to a concrete form, preventing concrete infiltration and allowing easy extension to match the finished wall surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard outlet boxes are used for concrete wall applications, then the box can be installed in the wall, but the box lacks secure attachment means to the form, resulting in potential displacement during concrete pouring
Solution Approach 1:
The attachment mechanism is segmented into multiple independent nail receptacles distributed around the box perimeter, allowing secure attachment at multiple points without requiring a complex integrated attachment system
Solution Approach 2:
The box includes built-in nail receptacles that automatically provide attachment capability when needed, eliminating the need for separate attachment devices or complex mounting mechanisms
2Ease of operation
If the outlet box is installed with standard depth, then the box can be mounted to the form, but the box depth is insufficient to remain flush with the finished wall surface after concrete pouring and finishing
Solution Approach 1:
The box includes a telescopic extension member that can be adjusted to different lengths, allowing the box depth to be dynamically changed to match various finished wall surface requirements without requiring different box sizes
Solution Approach 2:
The extension member allows the effective depth parameter of the box to be changed by telescoping to different positions, enabling the box to adapt to different wall finishing thicknesses
3Reliability
If the outlet box is installed before concrete pouring, then the box can be positioned in the wall, but concrete may infiltrate into the box interior, causing the box to become filled and unusable
Solution Approach 1:
The box includes a removable knockout member that can be taken out before concrete pouring to allow concrete to be poured around the box, and then replaced afterward to seal the opening and prevent future infiltration
Solution Approach 2:
The knockout member acts as an intermediary element that temporarily opens the box interior to the exterior during pouring, then seals it afterward, mediating between the need for concrete placement and the need for box protection
4Length of stationary object
If the outlet box requires separate extension attachments, then the box can be extended to match the finished wall surface, but the installation process becomes more complex and time-consuming
Solution Approach 1:
The extension functionality is merged into the box structure itself through the telescopic extension member, eliminating the need for separate extension attachments and reducing installation steps
Solution Approach 2:
The telescopic extension member provides multiple functions: it extends the box depth, allows adjustment for different wall finishes, and integrates the extension mechanism directly into the box structure, reducing the need for additional components
Data Source
AI summary
An electrical outlet box for accommodating an electrical fixture includes a generally rectangular box having a back wall, a perimetrical side wall surrounding said back wall defining an open front face and a box interior, said side wall includes of a first and second set of generally parallel spaced apart wall portions; and a slidable extension nested within said generally rectangular box, that can be moved from within the generally rectangular box to an extended position beyond the open front face.