3D Printed Wall Bracket for Electrical Box Positioning
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Solution Overview
Problem
Conventional installation systems for electrical installations in 3D printed building walls face inaccuracies in positioning and fastening, with excess construction foam contaminating the wall surfaces and installation boxes being prone to displacement when filled with concrete.
Innovation Solution
An installation system comprising a holder with a frame and foot structure that can be inserted into the building wall, featuring positioning ribs and wings to securely anchor the installation box, ensuring accurate placement and protection from deformation, along with a method for integrating this system during the 3D printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If construction foam is used to fasten installation boxes in 3D printed building walls, then the installation boxes can be easily installed, but the positioning accuracy deteriorates and excess foam contaminates the wall surfaces
Solution Approach 1:
The installation system is divided into separate modular components: a holder with frame structure that provides positioning, and an installation box that fits into the holder. This segmentation allows the holder to handle positioning accurately while the installation box remains easy to install and remove.
Solution Approach 2:
The holder acts as an intermediary component between the building wall and the installation box. It provides a stable mounting structure with frame and foot elements that ensure accurate positioning, while the installation box can be easily attached to the holder without directly contacting the building wall.
2Ease of operation
If construction foam is used to fasten installation boxes, then installation is simplified, but excess foam oozes out and requires laborious removal
Solution Approach 1:
The harmful element (construction foam) is extracted from the installation process. Instead of using foam to fasten the installation box directly to the building wall, the system uses a mechanical holder structure that eliminates the need for foam, thereby preventing contamination entirely.
Solution Approach 2:
The system uses a reusable holder structure that provides permanent mechanical fastening, replacing the disposable nature of construction foam. This eliminates the need to clean up foam residue while maintaining ease of installation through simple attachment to the holder.
3Ease of operation
If installation boxes are fastened with construction foam, then installation is easier, but the boxes can be pushed out when the cavity is filled with concrete
Solution Approach 1:
The holder incorporates a frame structure with geometric shapes (rectangular frame, T-shaped cross section) that provide mechanical interlocking. This curved and angular geometry creates physical barriers that prevent the installation box from being pushed out, offering reliable fastening that foam cannot provide.
Solution Approach 2:
The holder is installed in advance into the building wall cavity, creating a pre-positioned mechanical anchor structure. This preliminary action ensures that when the installation box is later attached, it is securely held in place by the holder's frame structure, preventing displacement during concrete filling.
4Manufacturing precision
If a holder with frame structure is used to position and fasten installation boxes, then positioning accuracy and reliability improve, but the device complexity increases
Solution Approach 1:
The holder with frame structure serves multiple functions simultaneously: it provides positioning accuracy through the frame geometry, mechanical fastening through the foot elements, and protection for the installation box. This multi-functionality reduces the need for separate components, thereby limiting the increase in complexity.
Solution Approach 2:
The holder combines several functional elements into a single integrated structure: the frame for positioning, the foot elements for fastening, and the overall structure for protection. By merging these functions into one component rather than using separate elements, the complexity increase is minimized while maintaining high positioning accuracy and reliability.
Data Source
Figure 1~3
Figure 4~5
Figure 6a~6e
AI summary
The present invention relates to an installation system (1) comprising a bracket (2) and an installation box (3) that can be inserted therein for electrical installations in 3D-printed building walls, as well as a method for manufacturing a 3D-printed building wall with an installation system (1). The bracket (2) has a frame (5) that surrounds a receiving space (4) and extends substantially in an axial direction. The frame comprises a base plate (6) and a top plate (7) arranged opposite the receiving space (4), as well as two side plates (8) extending between the base plate (6) and the top plate (7) and laterally delimiting the receiving space (4). Furthermore, the bracket (2) has at least one foot structure (9) which serves to position the bracket (2) relative to a printed layer of the building wall during its manufacture.