Socket junction box

Abstract

A socket junction box disclosed by the present invention comprises a box body made of a galvanized sheet material and two installation supports oppositely arranged in a cavity of the box body, the installation supports are formed by integrally punching galvanized sheets, and the box body is provided with a bottom surface and side walls extending obliquely upwards around the periphery of the bottom surface. Bottom surface recesses recessed towards the inside of the box body are formed in the four corners of the bottom surface, and mounting holes are formed in the centers of the bottom surface recesses and provided with turnups extending towards the inside of the box body. The mounting support comprises a mounting plate, supporting legs, a connecting plate and a barrel-shaped convex hull, the mounting plate, the supporting legs and the connecting plate are integrally formed, an opening of the barrel-shaped convex hull faces downwards, an internal thread face is arranged in the convex hull and can be in threaded connection with a screw penetrating through the mounting hole in the bottom face, and therefore the mounting support is fixedly mounted on the bottom face of the box body.

Description

Technical Field

[0001] This invention relates to the field of junction box technology, and more particularly to a junction box that can provide stable support for a socket. Background Technology

[0002] Currently, socket junction boxes, as key components in electrical installations, are widely used in various scenarios such as homes, industrial plants, and commercial buildings. They are mainly used to house the socket body, protect the internal wiring structure, and also serve to fix the socket and guide the wiring.

[0003] Existing socket junction box mounting brackets generally fall into two extreme categories: one is an overly simple structural design, which reduces manufacturing costs but makes it difficult to provide sufficient stable and reliable support after actual installation. This can easily lead to loosening or displacement due to external forces, causing the socket to shift and affecting the plugging and unplugging experience, or even causing poor contact. The other category has a more complex structural design, which may result in difficulty in ensuring overall assembly accuracy due to the large number of parts and accumulated errors in the manufacturing process. This can affect the structural stability of the junction box after installation and its long-term safety.

[0004] Furthermore, traditional junction boxes are relatively limited in their material selection, with most products still using ordinary engineering plastics or untreated metal materials. While these materials may meet the needs of general indoor environments, their mechanical strength and anti-aging capabilities are often insufficient in special environments—such as humid spaces, high-temperature locations, and industrial sites with corrosive gases—making it difficult to guarantee durability and safety requirements during long-term use. Summary of the Invention

[0005] The purpose of this invention is to provide a socket junction box to solve the technical problems existing in the prior art.

[0006] To achieve the above objectives, the specific technical solution of the present invention is as follows:

[0007] A socket junction box includes a galvanized sheet body and two mounting brackets disposed opposite each other within the cavity of the body. The mounting brackets are integrally stamped from the galvanized sheet. The body has a bottom surface and side walls extending obliquely upwards around the bottom surface. The four corners of the bottom surface have recesses that curve inwards into the body. A mounting hole is provided at the center of each recess, and the mounting hole has a flange extending inwards into the body. The mounting bracket includes an integrally formed mounting plate, support feet, a connecting plate, and a downward-opening cylindrical protrusion. The protrusion has an internal threaded surface that can be threadedly connected to a screw passing through the mounting hole in the bottom surface, thereby fixing the mounting bracket to the bottom surface of the body.

[0008] Preferably, the inner surface of the opening of the convex bulge is a smooth cylindrical surface, and the diameter of the smooth cylindrical surface matches the outer diameter of the flange of the bottom mounting hole; the opening of the convex bulge can be fitted onto the outside of the flange of the bottom mounting hole, and the smooth cylindrical surface of the opening and the outer surface of the flange of the mounting hole form a tight fit to achieve a liquid seal.

[0009] Preferably, the mounting plate has a square plate structure and multiple mounting holes are provided on the mounting plate; two downwardly curved backing plates are formed at the rear edge of the mounting plate, and several horizontally extending convex plates with mounting holes are formed at the front edge of the mounting plate.

[0010] Preferably, the support foot is formed by bending downwards at 94° from the left and right ends of the mounting plate and extending to the bottom surface of the box; the connecting plate is formed by bending horizontally at the end of the support foot and extending a certain distance; and the bulge is formed by protruding upwards from the center of the connecting plate.

[0011] Preferably, the sidewall includes a front sidewall and a rear sidewall disposed opposite to each other, and two opposite left sidewalls and right sidewalls connecting the front sidewall and the rear sidewall, each sidewall forming a 94° angle with the bottom surface.

[0012] Preferably, the lower middle part of the front and rear sidewalls forms a sidewall recess that is recessed into the box body, and the recess depth of the upper part of the sidewall recess is slightly greater than that of the lower part, so that the bottom wall of the recess is perpendicular to the bottom surface of the box body; a wire hole with a flange extending into the box body is provided in the center of the sidewall recess, and the power supply line passes through it.

[0013] Preferably, the bottom surface has a bottom hole at its center, and the bottom hole has a flange extending into the interior of the box; the top surface opposite the bottom surface is an open opening, which is closed by a cover plate, and the cover plate is provided with a flip cover.

[0014] Preferably, a transition plate is integrally formed on any of the support feet at the bottom of the mounting plate. The transition plate is perpendicular to the support foot and extends inward. The lower end of the transition plate extends obliquely downward to form a grounding seat. A grounding hole is provided on the grounding seat, and a grounding screw is installed in the grounding hole for connecting the grounding wire.

[0015] Preferably, a fixing plate is installed in the bottom recess by screws, and the thickness of the fixing plate is not greater than the depth of the bottom recess; the fixing plate has two ends, one end is a round head and the other end is a notched flat head, and the notched edge of the notched flat head and the flat head edge form a 45° angle; both ends of the fixing plate are provided with through holes.

[0016] The beneficial effects of this invention are:

[0017] 1. This invention significantly improves the overall structural strength by ingeniously designing and integrally connecting the various functional structures of the mounting bracket. The internal threaded surface of the downward-opening cylindrical convex bulge can form a stable and reliable threaded connection with the screw passing through the mounting hole on the bottom surface, making the connection between the mounting bracket and the bottom surface of the box firm and reliable. This effectively avoids loosening or displacement caused by external forces, ensures the stability of the socket after installation, and improves the plugging and unplugging experience and electrical safety.

[0018] 2. The tight fit between the smooth cylindrical surface of the convex opening and the flange of the mounting hole on the bottom surface of the present invention achieves a liquid seal, which can effectively prevent external liquids or dust from entering the box and protect the internal wiring structure.

[0019] 3. The galvanized sheet material used in this invention has excellent corrosion resistance. By forming a dense zinc coating on the surface of the steel sheet, the galvanized sheet can effectively isolate the contact between air, moisture and other corrosive media and the substrate, significantly improving the durability of the junction box in special environments such as humid environments, high-temperature places and industrial places with corrosive gases. Attached Figure Description

[0020] Figure 1 This is a three-dimensional schematic diagram of the structure of the present invention;

[0021] Figure 2 This is a three-dimensional schematic diagram of the box structure of the present invention;

[0022] Figure 3 This is a three-dimensional schematic diagram of the mounting bracket structure of the present invention;

[0023] Figure 4 This is a front view schematic diagram of the mounting bracket structure of the present invention;

[0024] Figure 5 This is a schematic diagram of the structure of the mounting and fixing piece recessed on the bottom surface of the box body of the present invention;

[0025] Figure 6 This is a three-dimensional schematic diagram of the recessed mounting and fixing piece on the bottom surface of the box body of the present invention;

[0026] Figure 7 This is a schematic diagram showing the state of the socket after installation of the present invention;

[0027] Figure 8 This is a schematic diagram showing the state of the present invention after the socket and cover plate are installed.

[0028] Explanation of reference numerals in the attached drawings: 10, housing; 11, bottom surface; 111, bottom recess; 1111, mounting hole; 112, bottom hole; 12, side wall; 121, front side wall; 122, rear side wall; 123, side wall recess; 124, wire hole; 20, mounting bracket; 21, mounting plate; 22, support foot; 221, transition plate; 222, grounding base; 23, connecting plate; 24, protrusion; 30, fixing piece; 40, cover plate; 41, flip cover; 50, socket. Detailed Implementation

[0029] To better understand the purpose, structure, and function of this invention, a socket junction box of this invention will be described in further detail below with reference to the accompanying drawings.

[0030] like Figure 1-8 As shown, the present invention provides a socket junction box, including a box body 10 made of galvanized sheet and a mounting bracket 20 disposed in the cavity of the box body 10. The mounting bracket 20 is also integrally formed of galvanized sheet. The box body 10 is hollow square in shape, and a socket 50 can be installed inside it. The box body 10 has a bottom surface 11 located at the bottom, and side walls 12 extending obliquely upward around the bottom surface 11. The side walls 12 include a front side wall 121 and a rear side wall 122 arranged opposite to each other, and two opposite left side walls 12 and right side walls 12 connecting the front side walls 121 and the rear side walls 122. Each side wall 12 forms a 94° angle with the bottom surface 11. Except for the bottom surface 11 and the side walls 12, the top surface of the box body 10 opposite to the bottom surface 11 is open to facilitate the installation of the socket 50. After the socket 50 is installed, the open surface can be closed by a cover plate 40.

[0031] A bottom hole 112 with a diameter of 19 mm is formed at the center of the bottom surface 11, through which the power supply cable passes. The bottom hole 112 has a flange extending 5.3 mm into the box body 10. Four square bottom surface recesses 111 are formed at the four corners of the bottom surface 11, which are recessed into the box body 10. A mounting hole 1111 is formed at the center of the bottom surface recess 111, and the mounting hole 1111 has a flange extending into the box body 10. Side wall recesses 123 are formed in the lower middle part of the front side wall 121 and the rear side wall 122, which are recessed into the box body 10. The recess depth of the upper part of the side wall recess 123 is slightly greater than that of the lower part, so that the bottom wall of the recess is perpendicular to the bottom surface 11 of the box body 10. A wire hole 124 with a diameter of 19 mm and a flange extending 5.3 mm into the box body 10 is formed at the center of the side wall recess 123, through which the power supply cable passes.

[0032] Two mounting brackets 20 are provided inside the cavity of the box body 10, arranged opposite each other, and respectively located on the inner side of the front side wall 121 and the rear side wall 122. The lower part of the mounting bracket 20 is fixedly installed on the bottom surface 11 of the box body 10. The mounting bracket 20 includes an integrally formed mounting plate 21, support feet 22, connecting plate 23, and protrusions 24. The mounting plate 21 has a square plate structure, and its length is adapted to the distance between the left and right side walls 12 of the box body 10. Its upper surface is slightly lower than the upper edge of the front and rear side walls 122. The mounting plate 21 has multiple mounting holes. Two downwardly curved backing plates are formed at the rear edge of the mounting plate 21. The backing plates are close to the inner surface of the front and rear side walls 122 of the box body 10, which play a role in positioning and stabilizing the mounting plate 21. Several horizontally extending protrusions with mounting holes are formed at the front edge of the mounting plate 21 to add mounting holes. The left and right ends of the mounting plate 21 are bent downward at 94° and extend to the box body 10. The bottom surface 11 forms two supporting legs 22. The ends of the two supporting legs 22 are horizontally bent and extend relative to each other by a certain distance to form two connecting plates 23. A cylindrical convex bulge 24 with an opening facing downward is formed at the center of the connecting plate 23. The inner surface of the convex bulge 24 is divided into two parts: the inner surface of the opening is a smooth cylindrical surface, and the inner surface above the opening is an internally threaded surface. The diameter of the smooth cylindrical surface matches the outer diameter of the flange of the mounting hole 1111 on the bottom surface 11, while the internally threaded surface matches the external thread of the screw. When the mounting bracket 20 is installed, the opening of the convex bulge 24 is fitted over the flange of the mounting hole 1111 on the bottom surface 11. The smooth cylindrical surface of the opening and the outer surface of the flange of the mounting hole 1111 form a tight fit to achieve a liquid seal. Then, the screw is passed through the mounting hole 1111 on the bottom surface 11 and screwed into the internally threaded surface of the convex bulge 24 to connect with it, thereby fixing the mounting bracket 20 to the bottom surface 11 of the box body 10.

[0033] On any of the support feet 22 at the bottom of the mounting plate 21, a transition plate 221 is integrally formed. The transition plate 221 is perpendicular to the support foot 22 and extends inward. The lower end of the transition plate 221 extends obliquely downward to form a grounding seat 222. A grounding hole is provided on the grounding seat 222, and a grounding screw is installed in the grounding hole for connecting the grounding wire to ensure electrical safety.

[0034] A fixing plate 30 is installed in the recess 111 on the bottom surface using screws. The thickness of the fixing plate 30 is not greater than the depth of the recess 111. The fixing plate 30 has two ends: one end is rounded and the other end is a notched flat end. The notched edge of the notched flat end forms a 45° angle with the flat end edge. Both ends of the fixing plate 30 have through holes. The through hole at the notched flat end is used to connect the fixing plate 30 to the bottom surface 11 of the box body 10 with screws, and the through hole at the round end is used to fix the entire box body 10 to the wall with screws. After the fixing plate 30 is properly installed, the flat end edge of the notched flat end just abuts against the side wall 12 of the recess 111 on the bottom surface, which can prevent the fixing plate 30 from rotating. During installation, the fixing plate 30 can also be rotated 45° as needed so that the notched edge abuts against the side wall 12 of the recess 111 on the bottom surface, so that the fixing plate 30 is installed at an angle.

[0035] In use, first install the mounting bracket 20 onto the bottom surface 11 of the box body 10. Then, fit the opening of the protrusion 24 on the connecting plate 23 at the end of the support leg 22 of the mounting bracket 20, which is integrally stamped from galvanized sheet, onto the outside of the flange of the mounting hole 1111 on the bottom surface 11. The smooth cylindrical surface and the outer surface of the flange fit tightly together to achieve a liquid seal. Then, place the fixing piece 30 into the recess 111 on the bottom surface. After passing the screw through the through hole at the notched flat end of the fixing piece 30 and the mounting hole 1111 on the bottom surface 11, screw it into the inner thread surface of the protrusion 24 to complete the fixation. This installation method not only provides a stable connection but also effectively prevents external moisture from entering the inside of the box body 10 through the gap in the mounting hole 1111. The power supply line is introduced into the cavity of the box 10 through the bottom hole 112 on the bottom surface 11 or the wire hole 124 in the side wall recess 123. After the wire is introduced, the socket 50 is placed on the mounting plate 21 of the two opposing mounting brackets 20. The socket 50 is then firmly fixed with screws through the mounting holes on the mounting plate 21. During installation, the grounding hole on the grounding base 222 of the mounting bracket 20 is connected to the grounding wire to safely conduct any leakage current that may be generated during the use of the socket to the ground, ensuring electrical safety. The box 10 is fixed by the fixing piece 30 in the bottom recess 111. During installation, the installation angle of the fixing piece 30 can be selected according to the wall structure requirements. During normal installation, the flat edge of the notched corner abuts against the side wall 12 of the bottom recess 111. If the installation direction needs to be adjusted, the fixing piece 30 is rotated 45° so that the notched corner abuts against the side wall 12 to achieve oblique installation, which enhances the flexibility of installation. After the socket 50 is installed and the wiring is completed, the cover plate 40 can be used to cover the open top surface of the box 10. A flip cover 41 can also be installed on the cover plate 40 to cover it, providing a certain degree of waterproofing. The entire installation process is simple and efficient. After installation, the socket 50, under the stable support of the mounting bracket 20, can effectively resist external forces, preventing loosening or displacement, and ensuring long-term structural stability and a good plugging and unplugging experience.

[0036] Both the junction box 10 and the mounting bracket 20 of the present invention are made of galvanized sheet material. Galvanized sheet material itself has excellent rust and corrosion resistance, which enables the junction box to maintain good durability in special environments such as humidity and corrosive gases, thus extending the service life of the product.

[0037] A process for manufacturing the socket junction box includes the following steps:

[0038] 1. Material cutting: Galvanized sheet is used as raw material. According to the unfolded dimensions of box body 10 and mounting bracket 20, the material is cut into flat sheet.

[0039] 2. Stretching: The blank of box body 10 is stretched and formed to form an integral cavity structure with bottom surface 11, four side walls 12, bottom surface recess 111, and side wall recess 123.

[0040] 3. Stamping: Punch holes and flanging are performed on the box body 10, and it is stamped into shape; the mounting bracket 20 is stamped into shape as a whole.

[0041] 4. Connection: Fit the protrusion 24 of the mounting bracket 20 onto the flange of the mounting hole 1111 of the box body 10 to form a tight fit, and use a screw to pass through the mounting hole 1111 and lock it with the internal thread of the protrusion 24.

[0042] 5. Powder coating: The surface of the assembled components is powder coated to achieve sealing and corrosion protection.

[0043] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," and "the other end," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0044] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0045] It is understood that the present invention has been described through some embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of the invention. Furthermore, under the teachings of the present invention, these features and embodiments can be modified to adapt to specific situations and materials without departing from the spirit and scope of the invention. Therefore, the present invention is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are within the protection scope of the present invention.

Claims

1. A socket junction box, comprising a galvanized sheet metal box body (10) and two integrally formed galvanized sheet metal mounting brackets (20) disposed opposite to each other within the cavity of the box body (10), characterized in that, The box (10) has a bottom surface (11) and side walls (12) extending obliquely upward around the bottom surface (11). The four corners of the bottom surface (11) form bottom surface recesses (111) that are recessed into the box (10). A mounting hole (1111) is provided in the center of the bottom surface recess (111). The mounting hole (1111) has a flange extending into the box (10). The mounting bracket (20) includes an integrally formed mounting plate (21), a support foot (22), a connecting plate (23), and a cylindrical protrusion (24) with an opening facing downward. The protrusion (24) has an internal thread surface that can be threadedly connected to a screw that passes through the mounting hole (1111) of the bottom surface (11), thereby fixing the mounting bracket (20) onto the bottom surface (11) of the box (10).

2. A socket junction box according to claim 1, characterized in that, The inner surface of the opening of the convex bulge (24) is a smooth cylindrical surface, and the diameter of the smooth cylindrical surface matches the outer diameter of the flange of the mounting hole (1111) on the bottom surface (11). The opening of the convex bulge (24) can be fitted onto the outside of the flange of the mounting hole (1111) on the bottom surface (11). The smooth cylindrical surface of the opening and the outer surface of the flange of the mounting hole (1111) form a tight fit to achieve a liquid seal.

3. A socket junction box according to claim 1 or 2, characterized in that, The mounting plate (21) is generally square plate structure, and multiple mounting holes are provided on the mounting plate (21); two downward curved backing plates are formed at the rear edge of the mounting plate (21), and several horizontally extending convex plates with mounting holes are formed at the front edge of the mounting plate (21).

4. A socket junction box according to claim 3, characterized in that, The support foot (22) is formed by bending downwards at 94° from the left and right ends of the mounting plate (21) and extending to the bottom surface (11) of the box body (10); the connecting plate (23) is formed by bending horizontally at the end of the support foot (22) and extending a certain distance; the bulge (24) is formed by protruding upwards from the center of the connecting plate (23).

5. A socket junction box according to claim 1 or 2, characterized in that, The sidewall (12) includes a front sidewall (121) and a rear sidewall (122) arranged opposite to each other, and two opposite left sidewalls (12) and right sidewalls (12) connecting the front sidewall (121) and the rear sidewall (122), with each sidewall (12) forming a 94° angle with the bottom surface (11).

6. A socket junction box according to claim 5, characterized in that, The lower middle part of the front sidewall (121) and the rear sidewall (122) are formed with sidewall recesses (123) that are recessed into the box body (10). The upper part of the sidewall recess (123) is slightly deeper than the lower part, so that the bottom wall of the recess is perpendicular to the bottom surface (11) of the box body (10). A wire hole (124) with a flange extending into the box body (10) is provided in the center of the sidewall recess (123), through which the power supply line passes.

7. A socket junction box according to claim 1 or 2, characterized in that, The bottom surface (11) has a bottom hole (112) at the center, and the bottom hole (112) has a flange extending into the box body (10); the top surface opposite to the bottom surface (11) is an open opening, which is closed by a cover plate (40), and a flip cover (41) is provided on the cover plate (40).

8. A socket junction box according to claim 1 or 2, characterized in that, On any of the support feet (22) at the bottom of the mounting plate (21), a transition plate (221) is integrally formed. The transition plate (221) is perpendicular to the support foot (22) and extends inward. The lower end of the transition plate (221) extends obliquely downward to form a grounding seat (222). A grounding hole is provided on the grounding seat (222), and a grounding screw is installed in the grounding hole for connecting the grounding wire.

9. A socket junction box according to claim 1 or 2, characterized in that, A fixing plate (30) is installed in the bottom recess (111) by screws. The thickness of the fixing plate (30) is not greater than the depth of the bottom recess (111). The fixing plate (30) has two ends, one end is a round head and the other end is a flat head with a notched corner. The notched corner side of the flat head and the flat head side form a 45° angle. Both ends of the fixing plate (30) are provided with through holes.

10. A process method for manufacturing the socket junction box according to claims 1-9, comprising the following steps:

1. Cutting: Using galvanized sheet as raw material, cut into flat sheet according to the unfolded dimensions of box body (10) and mounting bracket (20); 2. Stretching: The blank of box body (10) is stretched and formed to form an integral cavity structure with bottom surface (11), four side walls (12), bottom surface recess (111), and side wall recess (123); 3. Stamping: Punch holes and fold the box body (10) and stamp it into shape; stamp the mounting bracket (20) into shape as a whole; 4. Connection: Fit the protrusion (24) of the mounting bracket (20) onto the flange of the mounting hole (1111) of the box body (10) to form a tight fit, and use a screw to pass through the mounting hole (1111) and lock it with the internal thread of the protrusion (24); 5. Powder coating: The surface of the assembled components is powder coated to achieve sealing and corrosion protection.

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