Installation box and method for manufacturing an installation box

Abstract

The present invention relates to an installation box (1) for electrical installations. The installation box (1) comprises a box body (2) with a tubular side wall (3) extending in an axial direction (x) from a front end (4) to a rear end (5), which surrounds an installation space (6) accessible via an installation opening (7) bordered by the tubular side wall (3) on the front, and a box base (11) opposite the installation opening (7). The tubular side wall (3) further forms at least one pocket (15) projecting outwards from the axial direction beyond an inner contour of the installation opening (7). The present invention further relates to a manufacturing method for such an installation box (1).

Description

[0001] The present invention relates to an installation box for electrical installations and a method for producing an installation box.

[0002] Installation boxes, among other things, are used to install electrical switches, sockets, lamps, appliances, etc., at the designated locations within a building. Such installation boxes include, for example, flush-mounted boxes, inlet boxes, flush-mounted junction boxes, distribution boxes, and the like. Installation boxes typically have a cylindrical or cuboid-shaped box body with a box base and a tubular side wall extending in an axial direction. These enclose an installation space accessible via an installation opening.

[0003] Nowadays, installation boxes are usually manufactured by injection molding, or the installation boxes include or are made of injection-molded materials. If such installation boxes are closed at the back and thus have a box base that merges into the side wall and is molded onto it, the installation space, viewed from the axial direction, is generally located within a (clear) cross-section, or rather an inner contour, of the installation opening. An example of such installation boxes is EP3540885 by the same applicant. This design of the installation box enables simple production by injection molding, with a core that is arranged in the installation space and can be removed through the installation opening. A disadvantage of such installation boxes, however, is that only limited installation space is available, and connecting the electrical installations can be complicated depending on the application.

[0004] Furthermore, installation boxes are known which have a rear mounting opening instead of a rear box base. An example of such installation boxes is EP3584898 by the same applicant. In this case, the installation box can be demolded via the mounting opening instead of the installation opening. In this case, the size of the installation space is determined by the rear mounting opening. However, such installation boxes have the disadvantage that the mounting opening must be provided with a cover and possibly a seal. This thus requires an additional assembly or production step (manufacturing and attaching the cover). This can also lead to increased manufacturing costs.

[0005] It is an object of the invention to provide an installation box that allows for simple installation of the electrical installation. Another object of the invention is to provide an installation box that can be easily manufactured and / or installed. Another object of the invention is to provide a simple method for producing such an installation box.

[0006] The installation box according to the invention comprises a box body with a tubular side wall extending in an axial direction from a front end to a rear end. The tubular side wall extends around a central axis of the installation box, which consequently also extends in the axial direction. The tubular side wall surrounds an installation space accessible via a front installation opening in the box body bordered by the tubular side wall. The tubular side wall can change its cross-section along the axial direction. For example, the tubular side wall can be round and / or square in sections when viewed from the axial direction. The tubular side wall further merges into a box base of the box body at the rear end. The box base is therefore opposite the installation opening.The can body (comprising the side wall and the can base) is advantageously designed in one piece.

[0007] According to the invention, the box body, or rather the tubular side wall, forms at least one pocket projecting radially outward beyond an inner contour of the installation opening when viewed from the axial direction. Advantageously, several pockets are provided. The pocket forms a pocket interior, which is part of the installation space. The expanded cross-section of the installation space provided by the pocket can, for example, accommodate excess lengths of installation cables without reducing the intended space for the actual electrical installation (e.g., a socket or similar).

[0008] The box body can be made of a hard plastic component. The box body advantageously has at least one layer of a hard plastic component surrounding the installation space. The layer of hard plastic component thus protects the installation space and preferably keeps it dimensionally stable, or the pocket is preferably dimensionally stable. A dimensionally stable pocket can protect the electrical installation from damage, for example, if external forces are applied to the installation box. Dimensionally stable means that the pocket cannot be compressed or turned inside out.

[0009] The box body can further comprise at least one insertion opening for inserting installation cables and / or installation pipes into the installation space. The installation opening can also be closable by a cover of the installation box, or the installation box can comprise a cover for closing the installation opening. Depending on the application, the installation box can further comprise additional elements and / or layers made of a soft-elastic material component, such as a soft-elastic membrane closing the insertion opening and / or a seal for sealing the cover against the box body. The elements made of the soft-elastic material component are advantageously formed on the box body and / or the cover. It is also conceivable for the installation box to comprise at least one further layer made of a different material, such asa layer of intumescent material which is at least partially molded or attached to the can body made of the hard plastic component.

[0010] As described, the box body can have at least one insertion opening. Furthermore, in an initial state (i.e. before assembly and / or in the sold state), the insertion opening can be closed by the flexible (pierceable) membrane or a detachable wall section. At least one insertion opening of the box body is advantageously arranged in the at least one pocket. The expanded cross-section of the installation space provided by the pocket can thus also accommodate installation conduit ends protruding into the installation space. A locking element for fastening an electrical installation conduit can additionally be provided in the pocket and on the at least one insertion opening. The pocket thus enables easy mounting of installation conduits and / or installation cables on the installation box.

[0011] The pocket advantageously has a substantially constant pocket depth in the axial direction at one circumferential position. Depending on the application, the pocket can alternatively or additionally border the box base. The pocket depth, viewed from the axial direction, is measured from the inner contour of the installation opening radially outwards to the inside of the pocket. In the circumferential direction, the pocket can also be curved outwards (pointing away from the central axis). Depending on the application, two structured surface elements can be arranged on the inside of the installation box, which provide an engagement surface for spreading claws of an electrical installation. The pocket is advantageously arranged circumferentially next to and / or axially below the surface elements.

[0012] Due to the pocket, the installation space has a variable cross-section in the axial direction. In a front area of ​​the installation space, this can therefore have (at least) a first cross-section perpendicular to the axial direction, and in a rear area of ​​the installation space, it can have (at least) a second cross-section that is larger than the first cross-section. Of course, there can also be several first cross-sections in the front area and several second cross-sections in the rear area. The front area of ​​the installation space can be surrounded by the front end of the tubular side wall and / or the rear area of ​​the installation space can be surrounded by the rear end of the tubular side wall. The front area advantageously extends over 5% - 40% of a length of the can body in the axial direction and / or the rear area over 60 - 95% of the length of the can body.In particular, however, the front area extends over 5% - 20% of the length of the can body and / or the rear area over 80 - 95% of the length of the can body. The (at least one) second cross-section can have at least one outwardly curved section, which lies radially outside the first cross-section. The outwardly curved section of the (at least one) second cross-section lies in the outwardly curved pocket of the installation space, as described in more detail above.

[0013] Depending on the application, at least one detachable wall region along a defined contour can be arranged in the tubular side wall. The at least one detachable wall region can extend in the axial direction. However, two detachable wall regions are advantageously provided. These are preferably arranged opposite one another with respect to the central axis of the tubular side wall. The two oppositely arranged wall regions can be oriented parallel to one another. The installation box advantageously comprises two detachable wall regions, between which the at least one pocket is arranged in the circumferential direction of the side wall.

[0014] Furthermore, fastening elements for securing an electrical installation in the installation box can be arranged at the front end of the tubular side wall. These can protrude into the installation space and / or into the installation opening. This means that they can be arranged, in particular molded, on an inner side of the tubular side wall.

[0015] Depending on the application, the installation box can further comprise a locking structure for operatively connecting a counter-locking structure of another installation box. The locking structure is advantageously arranged on an outer side of the tubular side wall. However, the locking structure can also be arranged on the cover closing the installation opening. The locking structure can comprise one or more locking elements, which advantageously have an undercut in the (respective) connection direction. The connection direction is the direction from which another installation box is moved towards the installation box for operatively connecting the counter-locking structure to the locking structure. The locking structure advantageously has at least one pair of locking elements. A pair of locking elements comprises a first and a second locking element.The first and second locking elements of a pair of locking elements are preferably arranged opposite one another in a circumferential direction of the installation box in relation to the (corresponding) detachable wall area. The first and the second locking elements can each have an undercut. The first locking element is advantageously designed to be operatively connected to a second locking element of the counter-locking structure of the further installation box, wherein the second locking element of the counter-locking structure is structurally identical to the second locking element of the locking structure. In addition, the second locking element can be designed to be operatively connected to a first locking element of the counter-locking structure, wherein the first locking element of the counter-locking structure is structurally identical to the first locking element of the locking structure. This design has the advantage that, for example,a 180° rotation of the installation box around the central axis with opposing detachable wall areas and locking structures has no effect on the operative connectivity. Depending on the design, the at least one first locking element can be designed without an undercut in a first direction (y-direction), which is arranged perpendicular to the axial direction (x-direction) and perpendicular to the connection direction (z-direction). The at least one second locking element can in turn be designed without an undercut in a second direction opposite to the first direction (negative y-direction). This is particularly advantageous when the installation box is manufactured by injection molding.

[0016] The removable wall area can comprise several separate or jointly removable sections. Depending on the application, the multiple sections can be arranged one behind the other in the axial direction. Each removable section can be surrounded at least in part by a seal. Alternatively or additionally, the seal can also surround several sections together, at least in part. At least one pair of locking elements can be present per section. This means that each section then has opposing first and second locking elements with respect to that section.

[0017] Depending on the application, at least two sections can be arranged one behind the other in the axial direction (a front section and a rear section and optionally at least one middle section). The front section can be adjacent to the installation opening. The aforementioned fastening elements can be arranged on an inner side of the front section, which faces the installation space. The fastening elements are advantageously molded onto the respective front section. By cutting out the front sections, the fastening elements can be removed. Furthermore, a pipe entry can be arranged in one or more sections, in particular in the rear and / or (if present) the middle section. The respective pipe entry can be closed by a removable or pierceable soft-elastic membrane.

[0018] The present installation box comprises at least one injection-molded material component. The installation box advantageously consists of at least one injection-molded material component, in particular a hard plastic component. However, the installation box can also comprise multiple injection-molded material components. For example, the installation box can comprise at least two injection-molded material components, such as the hard plastic component and the flexible material component, or the hard plastic component and an intumescent material component.

[0019] The present invention further relates to a method for producing an installation box for electrical installations. The installation box has a box body made of a hard plastic component with a tubular side wall extending in an axial direction from a front end to a rear end, which tubular side wall surrounds an installation space. The installation space is accessible via a front installation opening bordered by the tubular side wall. Opposite the installation opening is a box base of the box body. Viewed from the axial direction, the tubular side wall further forms at least one pocket projecting outward beyond an inner contour of the installation opening. The pocket forms a pocket interior, which is part of the installation space.The said installation box is manufactured by injection molding, whereby after the injection molding of the installation box, it is demolded through a folding core arranged in the installation space, which can be removed at the front through the installation opening.

[0020] Advantageously, the folding core's cross-section can be adjusted at a distal end, particularly in its cross-section perpendicular to the axial direction. The axial direction of the installation box corresponds to the demolding direction of the folding core.

[0021] The folding core can advantageously be adjustable from a first position to a second position. In this case, the distal end of the folding core can have a first outer contour when viewed from the axial direction in the first position and a second outer contour when viewed from the axial direction in the second position. In this case, only the second outer contour (but not the first outer contour) lies within the inner contour of the installation opening. The distal end of the folding core is the end of the folding core that is arranged in the installation space after the installation box has been injection molded. In other words: the distal end is the part of the folding core that must be demolded from the installation box after it has been sharpened.The method according to the invention can therefore comprise the method step according to which the folding core is in the first position during injection molding, is brought into the second position after injection molding, before the folding core, which is arranged in some areas (ie with its distal end) in the installation space after injection molding, is demolded through the installation opening in the axial direction of the installation box.

[0022] If the installation box has elements or layers made of the soft-elastic material component (such as a membrane closing the insertion opening and / or a seal), the installation box is manufactured using a two-component injection molding process. The process can therefore comprise the further process step of first injection-molding the box body from the hard plastic component and then injection-molding additional elements and / or layers made of a soft-elastic material component onto the box body (such as a membrane closing the insertion openings of the box body made of the hard plastic component and / or a seal). The folding core preferably remains arranged in the installation space during the injection molding of the hard plastic component and the injection molding of the soft-elastic material component and is only then removed from the front through the installation opening.

[0023] For this purpose, the folding core can have a base and at least one segment movable relative to the base. The number of movable segments can correspond to the number of previously described pockets in the installation space. If multiple segments are present, these can be operatively connected to one another. The base preferably has a sliding surface along which a corresponding sliding surface of the segment can slide when the folding core is moved from the first position to the second position (or vice versa). Depending on the method, the folding core can further have a control system that controls the unfolding and refolding movements of the folding core. This control system can be electronic, pneumatic, or hydraulic.

[0024] Depending on the process, it may be advantageous for the first outer contour and the second outer contour of the distal end of the folding core to have at least three positioning corners, which maintain their respective positions unchanged in the first and second positions of the folding core. However, the folding core advantageously comprises at least four positioning corners. The positioning corners are preferably located at the base of the folding core. This means that the base of the folding core can be in contact with the installation box. The positioning corners serve to position the injection-molded installation box when the folding core is demolded.

[0025] Depending on the design, the installation box can have fastening elements for securing an electrical installation in the installation box in the area of ​​the front end of the tubular side wall, which protrude into the installation space and / or the installation opening. In this case, it is advisable for the second outer contour of the distal end of the folding core to be reduced in size perpendicular to the axial direction so that it can be demolded from the installation opening and past the fastening elements. For this purpose, the folding core can have additional (movable) segments that fill the installation space behind the respective fastening elements during injection molding.

[0026] Aspects of the invention are explained in more detail with reference to the exemplary embodiments shown in the following figures and the associated description. They show: Fig. 1 A first variant of an installation box according to the invention in a perspective view; Fig. 2 The installation box according to Fig. 1 in a side view; Fig. 3 The installation box according to Fig. 1 in a view from above; Fig. 4 Representation of an installation box according to the invention with a schematic sketch of a folding core.

[0027] Fig. 1 shows a first variant of an installation box 1 according to the invention in a perspective view, while Fig. 2 this installation box 1 in a view from the side and Fig. 3 in a view from above.

[0028] The installation box 1 shown comprises a box body 2 with a tubular side wall 3 extending in an axial direction (x-direction) from a front end 4 to a rear end 5. The tubular side wall 3 surrounds an installation space 6. This is accessible via a front installation opening 7 bordered by the tubular side wall 3. Opposite the installation opening 7 is a box base 11 of the box body 2, which merges into the tubular side wall 3.

[0029] As in particular in Fig. 2 and Fig. 3, the tubular side wall 3, viewed from the axial direction, forms at least one pocket 15 projecting outwardly beyond an inner contour of the installation opening 7. In the side view in Fig. 2, the U-shaped pocket 15 is clearly visible. The installation space 6 thus has a variable cross-section in the axial direction. In the front region 13 of the installation space 6, it has (at least) a first cross-section perpendicular to the axial direction, and in the rear region 14 of the installation space 6, it has (at least) a second cross-section that is larger than the first cross-section.

[0030] Two wall regions 9 of the tubular side wall 3 are arranged between the two opposing pockets 15. These can be separated along a defined contour 8. In the present case, the two wall regions 9 are opposite each other with respect to the central axis of the tubular side wall 3.

[0031] As in Fig. 1, the detachable wall area 9 can comprise several separate or joint detachable sections 16. In the present example, three sections 16a, 16b 16c are present. The three sections 16a, 16b 16c are arranged one behind the other in the axial direction. In the present example, the middle section 16b and the rear section 16c each have a detachable membrane 17. On the front section 16a, fastening elements 18 can be formed on an inner side, which protrude into the installation space 6 or into the installation opening 7. On an outer side of the tubular side wall 3, a locking structure 10 can also be seen. The locking structure 10 serves to operatively connect a counter-locking structure of a further installation box from a connection direction (z-direction).For easy stringing together of identical installation boxes, the locking structure 10 can comprise at least one pair of locking elements (per detachable wall area 9) with a first and a second locking element 19, 20.

[0032] Fig.4 shows an installation box 1 with a schematically illustrated folding core 21 shortly after the installation box 1 has been manufactured by injection molding. While the folding core 21 is still arranged with a distal end 22 in the installation space 6 of the installation box 1 during injection molding, this is removed through the installation opening 7 after injection molding. During injection molding, the folding core 21 is in a first position. For demolding, the folding core 21 is then moved from the first position to a second position. The distal end 22 of the folding core 21 in the first position has a first outer contour when viewed from the axial direction and a second outer contour in the second position when viewed from the axial direction. In this case, only the second outer contour fits through the installation opening 7. In the second position, the folding core 21 is removed from the installation space 6 through the installation opening 7.

[0033] The folding core 21 can have a base 23 and at least one segment 24 movable relative to the base 23. If, as shown, several segments 24 are present, these can be operatively connected to one another. The base 23 preferably has a sliding surface (not shown), along which a corresponding sliding surface of the respective segments 24 can slide when the folding core 21 is moved from the first position to the second position (or vice versa). Depending on the method, it can be advantageous if the first outer contour and the second outer contour have at least three positioning corners 25, which maintain their respective positions unchanged in the first and second positions of the folding core 21. In the case shown, the folding core 21 comprises four positioning corners 25.The positioning corners 25 are arranged on the base 23 of the folding core 21 and are in contact with the edges of the detachable wall area 9 of the installation box 1 during injection molding. LIST OF REFERENCE SYMBOLS 1 installation box 2 can bodies 3 side wall 4 Front end 5 Rear end 6 Installation room 7 Installation opening 8 Contour 9 Wall area 10 locking structure 11 Can bottom 12 paragraph 13 Front area 14 Rear area 15 bag Section 16 17 Membran 18 Fastening element 19 First locking element 20 Second locking element 21 folding core 22 Distal end 23 Base 24 segments 25 Positioning corner QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] EP 3540885

[0003] EP 3584898

[0004]

Claims

[1] Installation box (1) for electrical installations, the installation box (1) comprising a can body (2) made of a hard plastic component with a tubular side wall (3) extending in an axial direction (x) from a front end (4) to a rear end (5), which tubular side wall (3) surrounds an installation space (6) accessible via a front installation opening (7) bordered by the tubular side wall (3), and a can base (11) opposite the installation opening (7); wherein b. the tubular side wall (3) forms at least one pocket (15) projecting outwards beyond an inner contour of the installation opening (7) when viewed from the axial direction. [2] Installation box (1) according to claim 1, characterized by that the can body (2) has at least one insertion opening which is arranged in the at least one pocket (15). [3] Installation box (1) according to claim 2, characterized by that the insertion opening is closed in an initial state by a wall region or a membrane (17). [4] Installation box (1) according to one of the preceding claims, characterized by that the pocket (15) is curved outwards in the circumferential direction. [5] Installation box (1) according to one of the preceding claims, characterized by that the pocket (15) has a substantially constant pocket depth in the axial direction at a circumferential position. [6] Installation box (1) according to one of the preceding claims, characterized by that the pocket (15) is dimensionally stable. [7] Installation box (1) according to one of the preceding claims, characterized by that the installation box (1) has a substantially polygonal outer contour in the area of ​​the front end (4). [8] Installation box (1) according to one of the preceding claims, characterized by that in the region of the front end (4) of the tubular side wall (3) fastening elements (18) for fastening an electrical installation in the installation box (1) are arranged, which protrude into the installation space (6) and / or the installation opening (7). [9] Installation box (1) according to one of the preceding claims, characterized by that the installation box (1) comprises at least one wall region (9) arranged in the tubular side wall (3) and detachable along a defined contour (8). [10] Installation box (1) according to claim 9, characterized by that the installation box (1) comprises two detachable wall areas (9) between which the at least one pocket (15) is arranged in a circumferential direction of the side wall (3). [11] Method for producing an installation box for electrical installations by injection moulding, wherein a. the installation box comprises a box body (2) made of a hard plastic component with a tubular side wall (3) extending in an axial direction (x) from a front end (4) to a rear end (5), which tubular side wall (3) surrounds an installation space (6) which is accessible via a front installation opening (7) bordered by the tubular side wall (3), and a box base (11) opposite the installation opening (7); wherein b. the tubular side wall (3) forms at least one pocket (15) projecting outwardly beyond an inner contour of the installation opening (7), viewed from the axial direction; and c. after the injection molding of the installation box (1), it is demolded by a folding core (21) arranged at least partially in the installation space, which is removable at the front through the installation opening (7). [12] Method according to claim 11, wherein the folding core (22) is variable in its cross-section at a distal end (22) of the folding core (21). [13] Method according to claim 12, wherein the folding core is adjustable from a first to a second position, wherein the distal end (22) of the folding core (21) has a first outer contour in the first position viewed from the axial direction and a second outer contour in the second position viewed from the axial direction. [14] Method according to one of the claims 13, wherein the first outer contour and the second outer contour have at least three positioning corners (25) which keep their respective position unchanged in the first and second positions of the folding core (21). [15] Method according to claim 13, wherein a. at the front end (4) of the tubular side wall, fastening elements (18) for fastening an electrical installation in the installation box (1) are arranged, which protrude into the installation space (6); and b. the second outer contour of the distal end (22) of the folding core (21) can be reduced in size when viewed from the axial direction in such a way that the latter can be demolded from the installation opening (7) and past the fastening elements (18).

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