Compact Flush-Mounted Box for Thin Hollow-Wall Installation
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Solution Overview
Problem
Conventional flush-mounted boxes for electrical base elements in hollow walls require larger dimensions due to the extension of clamp screws and active parts, necessitating larger cover frames that are aesthetically undesirable and often require skilled plastering for installation.
Innovation Solution
A flush-mounted box with minimal dimensions, utilizing clamps on a circular outline of 28.5 mm or less, allowing secure installation without plastering, and optionally using a click system to fit closely around the electrical base element, reducing or eliminating the need for a cover frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If conventional flush-mounted boxes are used with clamp screws extending to the open front, then the box can be secured in thin hollow walls, but the box dimensions become larger than necessary and require larger cover frames
Solution Approach 1:
The clamp mechanism is divided into separate components: a clamp body mounted in the side wall and a clamp arm that can be moved independently. This segmentation allows the clamp arm to extend to the open front for securing thin walls while the main box body remains compact, resolving the contradiction between box size and installation reliability.
Solution Approach 2:
The clamp mechanism utilizes the lateral dimension of the side wall rather than extending the box depth. By mounting clamps in the side wall and having them extend forward, the solution achieves secure attachment in thin walls without increasing the box's primary dimensions, effectively using a different spatial dimension.
2Length of moving object
If clamp screws extend almost to the open front to secure thin hollow walls, then installation in thin walls is possible, but the active part of the electrical base element must extend to the open front and clamp screws extend next to it
Solution Approach 1:
The clamp function is extracted from the main box body and implemented as separate clamp components mounted in the side wall. This extraction allows the clamp arms to extend to the open front without interfering with the electrical base element installation, as the clamps are positioned laterally rather than occupying the central installation space.
Solution Approach 2:
The clamp arm acts as an intermediary between the box body and the thin hollow wall. It extends from the side wall mounting point to the open front, providing the necessary reach for securing thin walls while being positioned laterally to avoid interfering with the electrical base element installation process.
3Area of stationary object
If larger cover frames are used to cover the open front, then the flush-mounted box can be properly covered, but the visual impact increases and aesthetics deteriorate
Solution Approach 1:
The clamp arms are designed as movable components that can be positioned as needed during installation. This dynamic positioning allows the clamps to be placed optimally for both securing the box and minimizing their visual impact, enabling smaller cover frames to be used while maintaining aesthetic appearance.
4Ease of manufacture
If plastering is used to eliminate the need for cover frames, then aesthetic appearance improves, but installation becomes labor intensive and requires skilled plastering
Solution Approach 1:
The clamp mechanism is designed to be self-contained and self-explanatory, requiring no additional plastering or finishing work. The clamps are mounted in a way that their operation is intuitive and does not require skilled plastering techniques, allowing installers to complete the installation using only the clamp mechanism itself.
Data Source
AI summary
The present invention relates to a flush-mounted box for installation in a hollow wall, comprising: a hollow body with an open base surface and a side wall, a flange, at least one clamp for clamping the flush-mounted box and a clamp screw through the clamp, wherein the hollow body can be placed in a cylindrical space up to the flange, wherein the cylindrical space has an inner diameter of 37 mm±4 mm, wherein the clamp screw of the at least one clamp is placed on a circular outline with a diameter of no more than 28.5 mm and wherein the circular outline and the cylindrical space are concentric. The invention also relates to an assembly of the flush-mounted box and an electrical base element and a method for installing an electrical base element in a hollow wall.