Flexible Electrical Junction Box with Expandable Bellows and Adjustable Bracket
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Solution Overview
Problem
Existing electrical junction boxes face challenges in accommodating lengthy exposed wiring, difficult placement in unique wall constructions, and cumbersome transportation due to their shape, as well as issues with fitting terminating connections and wire nuts.
Innovation Solution
Development of flexible electrical junction boxes made from materials like flexible PVC and sturdy PVC, with features such as expandable sections, mounting brackets, and stackable designs to accommodate various wiring lengths and placements, and improved mounting systems for easier installation and transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional rigid junction boxes are used, then structural strength is maintained, but adaptability to unique wall constructions deteriorates
Solution Approach 1:
The junction box incorporates a flexible bellow section that can expand and contract to adapt to different wall constructions and spacing requirements. This flexible membrane allows the box to conform to unique installation environments while maintaining structural integrity through its controlled flexibility.
Solution Approach 2:
The junction box transitions from a static rigid structure to a dynamic system with expandable and collapsible sections. The bellows mechanism enables the box to change its dimensions dynamically during installation to fit various wall depths and configurations, then stabilize for use.
2Productivity
If multiple junction boxes are transported separately, then individual box functionality is maintained, but transportation efficiency deteriorates
Solution Approach 1:
The junction boxes are designed with nesting capabilities where one box can be placed inside another when collapsed. This nesting arrangement significantly reduces transportation space requirements and improves logistics efficiency while maintaining the functional integrity of each individual box.
Solution Approach 2:
The junction box is divided into modular sections including collapsible sides and detachable components. This segmentation allows the boxes to be disassembled or collapsed into compact forms for efficient stacking and transportation, then reassembled at the installation site.
3Adaptability or versatility
If junction boxes are designed with fixed dimensions, then manufacturing simplicity is maintained, but accommodation of lengthy wiring deteriorates
Solution Approach 1:
The junction box incorporates expandable bellows sections that can extend to accommodate lengthy wiring and large termination configurations. These dynamic expansion sections allow the box to adapt its internal volume during installation without requiring multiple fixed-size box variants, maintaining manufacturing simplicity.
Solution Approach 2:
The junction box design allows for parameter changes in its dimensions through the expandable bellows mechanism. The box can transition from a compact form during transportation to an expanded form during installation to accommodate varying wiring lengths and termination requirements, eliminating the need for multiple fixed-dimension box types.
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 flexible and adaptable design allows for easier installation in unique spaces, accommodates lengthy wiring, and facilitates efficient transportation and use of multiple boxes, enhancing safety and convenience in electrical installations.
Implementation Method 1
at least one flexible material operable to form an electrical junction box
Data Source
AI summary
Electrical accessories and associated methods of use and manufacture are provided. In one embodiment, an electrical accessory can be provided. The electrical accessory can include an electrical junction box having a first side wall. The electrical accessory can also include an adjustable bracket coupled to the electrical junction box. The adjustable bracket can include a sliding plate and a mounting plate. The sliding plate can be positioned adjacent the first side wall and can be removably coupled to the electrical junction box. The adjustable bracket can also include a mounting hole axially aligned with the mounting hole of the first side wall of the junction box. The axially aligned mounting holes can be configured to receive a screw such that rotation of the screw moves the sliding plate and electrical junction box in relation to the mounting plate.