Electric Box with Stretchable Annular Part for Varying Partition Thickness
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Solution Overview
Problem
Existing electrical boxes struggle with tedious installation, especially when dealing with varying plasterboard thicknesses, as current fastening mechanisms are either cumbersome or limited to specific panel thicknesses.
Innovation Solution
An electrical box design featuring an axially stretchable annular part made of rigid material, allowing adjustable distance between the shoulder and flaps for secure snapping into place across different wall thicknesses, combined with flexible flaps and a mechanism for easy deployment and retraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional fastening mechanisms with claws and screws are used, then the electrical box can be fixed in plasterboard panels of varying thicknesses, but the installation becomes tedious and time-consuming
Solution Approach 1:
The patent applies the dynamics principle by making the annular part deformable and stretchable, allowing it to dynamically adapt to different plasterboard thicknesses. The annular part can be stretched during installation to accommodate thicker panels and naturally returns to its undeformed state for thinner panels, eliminating the need for manual adjustment of fastening mechanisms and significantly reducing installation time while maintaining versatility across varying thicknesses.
Solution Approach 2:
The patent changes the physical state and dimensions of the annular part by stretching it during installation. This parameter change allows the annular part to expand and accommodate the plasterboard thickness, enabling the flaps to be positioned at the correct distance from the shoulder for any panel thickness. After installation, the annular part returns to its original state, securing the flaps in place without requiring manual intervention.
2Ease of operation
If latching flaps with automatic clipping are used, then the installation becomes easier, but the electrical box can only be used on plasterboard panels with specific thicknesses
Solution Approach 1:
The patent combines the ease of automatic clipping with adaptability to different thicknesses by making the annular part dynamic and stretchable. During installation, the annular part is stretched to accommodate the specific plasterboard thickness, allowing the flaps to automatically clip into place. After installation, the annular part returns to its undeformed state, maintaining the secure connection. This dynamic adjustment enables easy installation across a wide range of plasterboard thicknesses, not just specific predetermined sizes.
Solution Approach 2:
The patent achieves universality by designing the annular part to serve multiple functions: it acts as a spacer to position the flaps at the correct distance, provides structural support, and enables adaptation to various plasterboard thicknesses. The stretchable nature of the annular part allows the same electrical box design to be universally applied to different panel thicknesses while maintaining easy automatic installation through the flap mechanism.
3Adaptability or versatility
If the annular part is made of flexible material, then the distance between shoulder and flaps can be adjusted, but the manufacturing cost increases and structural solidity decreases
Solution Approach 1:
The patent applies the flexible shell principle by using a thin, stretchable annular part made of a material that can be elastically deformed. This annular part functions similarly to a flexible membrane, allowing it to be stretched during installation to accommodate different plasterboard thicknesses and then return to its original shape. The use of a thin, elastic material rather than a thick flexible component keeps manufacturing costs low while providing the necessary adjustability and structural integrity.
Solution Approach 2:
The patent uses dynamics by employing an annular part that transitions from a stretched state during installation to a relaxed state during operation. This dynamic behavior allows the same rigid material to provide both adjustability (when stretched) and structural solidity (when relaxed), eliminating the need for expensive flexible materials while maintaining the ability to adjust the distance between the shoulder and flaps for different plasterboard thicknesses.
4Ease of manufacture
If the annular part is made of rigid material, then manufacturing costs are reduced and structural solidity is improved, but the distance between shoulder and flaps cannot be adjusted
Solution Approach 1:
The patent resolves this contradiction by introducing dynamics to the rigid annular part. Although made of rigid material for cost-effectiveness and structural strength, the annular part can be temporarily deformed (stretched) during installation to accommodate different plasterboard thicknesses. After installation, it returns to its original rigid state, providing both the manufacturability and structural benefits of rigid materials and the adaptability of flexible components.
Solution Approach 2:
The patent applies preliminary action by pre-designing the rigid annular part with inherent elastic properties that allow temporary deformation. The annular part is manufactured in a specific shape and size that enables it to be stretched to accommodate various plasterboard thicknesses during installation. This preliminary design of the rigid component's geometry allows it to perform the adjustment function without requiring additional flexible materials or complex mechanisms, maintaining low manufacturing costs while achieving adaptability.
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
Facilitates easy installation on a wide range of plasterboard thicknesses, enhances airtightness, and reduces manufacturing costs while ensuring structural solidity, meeting low building consumption standards.
Implementation Method 1
by stretching the annular part, it is possible to adjust the distance separating the shoulder of the flaps
Implementation Method 2
because the annular part has a natural tendency to return to its undeformed state, the flaps and the shoulder firmly sandwich the edge of the opening in the wall
Data Source
Figure 1~3
Figure 4
AI summary
The invention relates to an electrical box (1) for installation in an opening made in a hollow partition panel, comprising a side wall (2) open at the front, a shoulder (51) adapted to bear against the front face of said panel and supported by a front portion (50) of the side wall, a fastening means (20) at the rear of said panel, supported by a rear portion (10) of the side wall, and an annular portion (80) located between the front and rear portions of the side wall. According to the invention, the annular portion is made of the same material as said shoulder and is axially deformable, and said fastening means comprises at least one flap (21) adapted to pivot between a retracted position in which it does not obstruct the insertion of the electrical box into said opening and a deployed position in which it hooks onto the rear of said panel.