Square Electrical Box Adaptor With Tabbed Collar for Gap-Free Mounting
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Solution Overview
Problem
Existing adaptors for square electrical boxes are not compatible with various mounting patterns of electrical devices and fixtures, and they often require unsightly cut-outs and patching in drywall or concrete block, leading to inefficient and aesthetically unpleasant installations.
Innovation Solution
An adaptor with a base and collar designed to fit square electrical boxes, featuring four substantially triangular tabs with openings for fastening, allowing compatibility with different mounting patterns and reducing cut-out size for easier and gap-free installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If current adaptors have circular or octagonal collar shapes, then they can be coupled to square electrical boxes, but they create unsightly gaps or openings in drywall that require time-consuming patching
Solution Approach 1:
The collar is designed with an asymmetric shape that has a first surface with an octagonal dimension for compatibility with electrical devices and a second surface with a substantially square dimension matching the electrical box. This asymmetric design allows the collar to bridge between the square electrical box and the octagonal mounting pattern of light fixtures, eliminating gaps in drywall while maintaining compatibility with both components.
2Device complexity
If current adaptors provide only two points of attachment, then they are simple in design, but they result in an unsatisfactory connection between the adaptor and electrical device
Solution Approach 1:
The collar is divided into four substantially triangular tabs spaced around its perimeter, with each tab containing mounting openings. This segmentation provides multiple attachment points (at least four) distributed around the collar, enabling secure attachment of electrical devices with various mounting patterns while maintaining structural integrity and simplicity in the overall adaptor design.
3Strength
If adaptors are designed to match the electrical box shape, then they provide secure attachment to the box, but they are not compatible with electrical devices having different mounting patterns
Solution Approach 1:
The collar serves multiple functions: its second surface with substantially square dimension provides secure attachment to the square electrical box, while its first surface with octagonal dimension and four triangular tabs with mounting openings enables compatibility with electrical devices having octagonal or other mounting patterns. This multi-functional design allows a single adaptor to interface between different geometric configurations.
Data Source
AI summary
An adaptor configured to be coupled to a square electrical box, the adaptor comprising: a base having a first base surface, a second base surface, an outer perimeter, and an opening extending therethrough; a collar defining the opening on the base, wherein the collar has a first collar surface facing the opening and a second collar surface facing the first base surface of the base, wherein the collar comprises four triangular tabs; wherein the first collar surface of the collar has an octagonal dimension; and wherein the second collar surface of the collar has a substantially square dimension.