Fast Set Screw Mounting Socket for Non-Metallic Electrical Boxes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical outlet boxes require manual threading or assembly of additional components for screw retention, which is time-consuming and costly, and lacks a single, efficient method for quick and secure installation of electrical devices.
Innovation Solution
The development of a non-metallic electrical wiring box with fast set screw mounting sockets that allow for quick installation of electrical devices by simply pushing screws into tapered, flexible sockets, providing pre-load force for secure retention without manual threading or additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual threading method is used to install screws in non-metallic boxes, then screw retention is achieved, but installation time and labor effort increase significantly
Solution Approach 1:
The mounting sockets are pre-formed with tapered threads and flexible wall sections during box manufacturing. This preliminary preparation eliminates the need for installers to manually thread screws, as the pre-formed sockets guide and secure screws upon simple insertion, directly resolving the contradiction between reliable retention and installation time.
Solution Approach 2:
The flexible wall sections of the mounting sockets automatically engage and secure the screws through their inherent elasticity and tapered geometry. The socket structure itself performs the retention function without requiring additional manual threading actions or separate retaining devices, making the system self-securing and eliminating labor-intensive steps.
2Productivity
If additional retaining components are added to achieve quick set installation, then installation speed improves, but device complexity and manufacturing cost increase
Solution Approach 1:
The mounting socket integrates multiple functions into a single component: it provides thread engagement, flexible retention, and structural support all within the box itself. By merging these functions into the socket design rather than using separate retaining clips or devices, the system achieves quick installation without increasing overall device complexity or component count.
Solution Approach 2:
The mounting socket structure itself provides the retention mechanism through its flexible wall sections and tapered geometry, eliminating the need for separate retaining components. The socket serves both as the mounting interface and the retention mechanism, simplifying the overall device while maintaining installation speed.
3Reliability
If traditional screw mounting with female threaded portions is used, then secure retention is achieved, but the process requires multiple steps and additional components
Solution Approach 1:
The mounting sockets are pre-formed with tapered threads and flexible wall sections during box manufacturing. This preliminary preparation eliminates the need for installers to manually thread screws, as the pre-formed sockets guide and secure screws upon simple insertion, directly resolving the contradiction between reliable retention and installation time.
Solution Approach 2:
The socket geometry transitions from a rigid cylindrical shape to a tapered form with flexible wall sections. This parameter change in the socket structure allows it to deform and grip the screw threads during insertion, then maintain secure retention, simplifying the installation process while ensuring reliable holding.
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
Enables rapid and secure installation of electrical devices with reduced installer effort and manufacturing costs, as screws are easily inserted and retained without the need for manual threading or assembly of separate retaining devices, enhancing productivity and reducing installation time.
Implementation Method 1
the flexible socket wall sections deflect outwardly upon insertion of a screw and engage the threads of the screw to provide a pre-load force
Data Source
AI summary
A non-metallic electrical wiring box having a fast set screw mounting socket for mounting electrical devices inside the box. The box includes a pair of side walls, a pair of end walls, a back wall, a front opening and one or more fast set screw mounting sockets in each end wall, or connected to each end wall, for receiving a mounting screw. Each socket includes: a socket wall, preferably a cylindrically-shaped wall, an interior wall surface, a first end, a second end and a mid-region. The first end corresponds to the front opening of the box and the mid-region is between the first and second ends of the fast set screw mounting socket. Each socket also has a center slot in the socket wall, which preferably bisects the socket wall and extends from about the mid-region to the second end of the socket and defines two or more flexible socket wall sections.