Cast One-Piece Outlet Box With Side Wall Mounting Projections
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Solution Overview
Problem
Wiring boxes face challenges in resisting environmental forces and maximizing working volume without increasing material costs, particularly due to design limitations that allow water and dirt entry and require multiple assembly processes.
Innovation Solution
The development of integral wiring boxes with a single-piece construction, featuring a circular base, side wall, internal and external mounting projections, and a mounting hub, all formed as a unified component, which enhances weatherproofing and structural integrity while minimizing material usage and assembly requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple-part construction is used with plates and housing, then assembly flexibility is improved, but sealing performance deteriorates allowing water and dirt entry
Solution Approach 1:
The patent merges the housing, mounting projections, and cover into a single integrated casting. The cover is formed as an integral part of the housing with recesses that receive mounting plates, eliminating separate sealing components and joints that would allow water and dirt entry while maintaining assembly flexibility through the integrated design.
2Strength
If steel strip is crimped to box for plate attachment, then plate security is improved, but manufacturing complexity increases
Solution Approach 1:
The mounting projections are integrated directly into the housing casting as permanent features with recesses designed to receive mounting plates. This eliminates the need for separate steel strips and crimping operations, maintaining secure plate attachment while significantly simplifying the manufacturing process to a single-casting operation.
3Adaptability or versatility
If mounting projections extend from back wall, then fixture mounting capability is improved, but working volume decreases
Solution Approach 1:
The patent positions mounting projections on the side walls rather than extending them from the back wall into the cavity. This dimensional repositioning allows fixtures to be mounted laterally without encroaching on the working volume inside the box, maintaining fixture mounting capability while maximizing the available wiring space.
4Adaptability or versatility
If box size is increased to offset working volume loss, then mounting capability is maintained, but material cost increases
Solution Approach 1:
By relocating mounting projections to the side walls, the patent maintains full mounting capability without increasing the overall box dimensions. The projections are positioned on the lateral surfaces, allowing fixtures to be mounted outwardly without requiring increased box depth or volume, thus avoiding additional material costs.
Data Source
AI summary
In an example an integral wiring box comprises: a circular base having a base wire access point; a side wall extended from a perimeter edge of the base forming a cavity having an internal surface and an external surface and a side wall wire access point; a base conduit extending from the base wire access point into the cavity; a side wall conduit extending from the side wall wire access point into the cavity; an internal mounting projection extending from the internal surface of the side wall into the cavity and free from attachment to the circular base, the internal mounting projection further comprising a mounting hole; and an external mounting projection extending from the external surface of the side wall away from the base, the external mounting projection further comprising a mounting hole; wherein a single mounting hub extends from the base into the cavity, wherein the base, side wall, internal mounting projection, external mounting projection, and mounting hub, are formed as a single component.