Double Stud Fastener Watertight Electrical Enclosure Mounting
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Solution Overview
Problem
Current mounting systems for watertight electrical enclosures require extensive electrical labor and may compromise the watertight seal, as they often necessitate removal and reinstallation of sub panels, and rely on gaskets that can be incorrectly installed, leading to potential water leakage over the enclosure's lifespan.
Innovation Solution
A dual-purpose fastener, referred to as the Double Stud™, is welded or secured to the enclosure's back, allowing for mounting from outside without removing the sub panel, eliminating the need for gaskets and providing a reliable watertight seal by integrating a threaded cylindrical bore and a weld point for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If mounting holes are provided in the back of the enclosure with gaskets and hardware, then the enclosure can be mounted without removing the sub panel, but the watertight seal may be compromised due to incorrect gasket installation
Solution Approach 1:
The invention extracts the problematic gasket component from the mounting system and replaces it with a welded stud fastener that creates a permanent, reliable seal through welding rather than relying on user-installed gaskets. The stud is welded directly to the enclosure back panel, eliminating the gasket installation step that causes sealing failures.
Solution Approach 2:
The invention replaces the mechanical gasket-based sealing system with a welding-based sealing system. Instead of using gaskets that require proper installation to seal mounting holes, the stud is welded directly to the enclosure, creating a permanent metallurgical bond that ensures watertight sealing without relying on user skill or additional components.
2Reliability
If welding is performed to secure the fastener to the enclosure, then a reliable watertight seal is achieved, but the mounting process becomes more complex requiring welding equipment and skills
Solution Approach 1:
The invention segments the mounting process into two distinct phases: (1) welding the stud to the enclosure back panel during enclosure fabrication or initial installation, and (2) mounting the sub panel to the protruding stud threads. This segmentation allows the welding step to be performed when welding equipment is readily available, while the final mounting can be done with simple hand tools.
Solution Approach 2:
The stud is welded to the enclosure back panel in advance, before the sub panel mounting operation. This preliminary welding action prepares the mounting interface beforehand, so that when it's time to mount the sub panel, the electrician only needs to attach it to the pre-prepared threaded stud without requiring welding equipment or skills at that moment.
3Reliability
If the sub panel is removed to mount the enclosure, then proper enclosure mounting is achieved, but extensive electrical labor is required to remove and reinstall electrical devices
Solution Approach 1:
The invention changes the mounting dimension by providing threaded receptacles that protrude from the enclosure back panel toward the interior space. This allows the sub panel to be mounted from the interior side of the enclosure without requiring removal of the sub panel or disruption of electrical devices mounted on the enclosure door or face.
Solution Approach 2:
The threaded stud fastener acts as an intermediary element that bridges the enclosure back panel and the sub panel. Instead of requiring direct contact between the enclosure and sub panel mounting holes (which would necessitate sub panel removal), the stud protrudes into the enclosure interior as a mediator, allowing the sub panel to be attached from the inside without disrupting external electrical devices.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The Double Stud™ fastener streamlines the mounting process, reduces labor costs, and ensures a watertight seal that meets UL50 and UL508A standards, eliminating the need for additional gaskets and hardware, while accommodating various enclosure types and installation clearances.
Implementation Method 1
A head is connected to the top of the cylindrical body and extends beyond an outer surface of the cylindrical body. The cylindrical body includes a threaded cylindrical bore having an opening in the top of the cylindrical body, and the threaded cylindrical bore extends into the cylindrical body.
Data Source
AI summary
A stud for mounting an enclosure having a body with a first diameter, a length, a top, and a bottom. A head is connected to the top of the cylindrical body and extends beyond an outer surface of the cylindrical body. A cylindrical extension is connected to the bottom of the cylindrical body having a second diameter less than the first diameter, and an outer surface of the cylindrical extension is threaded. The cylindrical body includes a threaded cylindrical bore having an opening in the top of the cylindrical body, and the threaded cylindrical bore extends into the cylindrical body.