Electrical Box Cover With Removable Hinge System
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Solution Overview
Problem
Traditional electrical box covers often suffer from hinge damage when opened excessively, limiting their usability and requiring careful handling to avoid damage during installation and removal.
Innovation Solution
The design incorporates a removable and reconnectable hinge system with offset male and female hinges, featuring angled retaining projections to secure the mounting rod, allowing the door to pivot 90 or 180 degrees without damaging the hinges, and includes a tab and engagement aperture for secure closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional hinge designs are used where the cover door rotates about hinge pins, then the door can be opened and closed, but the hinges are damaged when opened excessively
Solution Approach 1:
The hinge system is divided into separate male and female hinge components that can be selectively engaged and disengaged. The male hinge includes a mounting rod that can be inserted into and removed from the female hinge, allowing the door to be opened without damaging the hinge connection.
Solution Approach 2:
The hinge design allows dynamic movement between connected and disconnected states. The mounting rod can rotate within the female hinge to allow door opening, and can be completely removed when excessive opening is detected, preventing damage while maintaining operational flexibility.
2Reliability
If the door is securely attached to the cover, then the electrical box is protected, but the door cannot be easily removed for installation and maintenance
Solution Approach 1:
The hinge connection is segmented into male and female parts that provide secure attachment during normal operation but can be easily separated when needed. The mounting rod fits into the female hinge to provide secure attachment, but can be simply pulled out for removal and maintenance.
Solution Approach 2:
The hinge design incorporates preliminary positioning features that guide the mounting rod into the female hinge during installation, ensuring proper alignment before final engagement. This makes the attachment process straightforward while maintaining secure connection during use.
3Ease of manufacture
If the hinge structure is simplified for easy manufacturing, then production cost is reduced, but the hinge may be damaged during excessive opening
Solution Approach 1:
The hinge is manufactured as separate male and female components using simple stamping or molding processes. The male hinge with mounting rod and the female hinge are produced independently using basic manufacturing techniques, keeping production simple while the modular design prevents damage through selective disengagement.
Data Source
AI summary
An electrical box cover including a body for securing a plurality of electrical connections therein, a cover having a door, the door having a first end with at least one male hinge, at least one female hinge attached to the cover, and wherein the at least one male hinge is removably connected with the at least one female hinge to selectively open and close the door.