Flush-Mounted Box Layout for Smaller Cover Frames in Hollow Walls
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Solution Overview
Problem
Conventional flush-mounted boxes for electrical base elements in hollow walls result in larger dimensions due to clamp screws extending close to the open front, necessitating larger cover frames that increase visual impact and aesthetic issues.
Innovation Solution
The flush-mounted box design incorporates protrusions that allow clamp screws to be positioned deeper within the box, with screw heads resting on a support surface at a distance from the open base surface, enabling a closer fit around the electrical base element and reducing the cover frame size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If clamp screws are positioned close to the open front to secure the flush-mounted box in thin hollow walls, then the box can be installed in walls with minimal thickness, but the box dimensions increase and require larger cover frames
Solution Approach 1:
The clamp screw is repositioned from a conventional location near the open front to a deeper position within the hollow body, utilizing the depth dimension. The protrusion structure extends the clamp's effective reach to the rear wall while allowing the screw head to rest on a support surface deeper inside the box, thereby securing thin walls without increasing the front-facing dimensions.
Solution Approach 2:
The clamp screw is nested within the hollow body structure, with the screw head resting on an internal support surface. The protrusion containing the clamp is positioned within the hollow body, allowing the clamping mechanism to reach the rear wall while the screw remains contained within the box's depth, eliminating the need for external screw placement.
2Area of stationary object
If clamp screws are positioned deeper within the box, then the cover frame size is reduced, but the clamp must reach further to secure the rear wall
Solution Approach 1:
The protrusion is designed with a specific length ratio where the extension distance A to the open base surface is at least 70% of the distance B from the open base surface to the support surface. This dimensional relationship ensures the clamp reaches sufficiently far to secure thin hollow walls while the screw head rests on the support surface at the deeper position, optimizing both reach and compactness.
3Area of stationary object
If the flush-mounted box dimensions are reduced to minimize cover frame size, then aesthetic appearance is improved, but the box must still accommodate the electrical base element and clamping mechanism
Solution Approach 1:
The hollow body is designed with a specific depth-to-diameter ratio and includes a strategically positioned support surface at distance B from the open base surface. The protrusion is configured with length A at least 70% of distance B, creating localized structural features that enable compact overall dimensions while providing sufficient space for the clamping mechanism and electrical base element.
Solution Approach 2:
The clamp screw is nested within the hollow body, with the screw head resting on the internal support surface. The protrusion containing the clamp is positioned within the hollow body, allowing the clamping mechanism to reach the rear wall while the screw remains contained within the box's depth, eliminating the need for external screw placement and reducing overall box dimensions.
Data Source
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AI summary
The present invention relates to a flush-mounted box for installation in a hollow wall, comprising: a hollow body with an open base surface and a side wall, a flange, at least two clamps for clamping the flush-mounted box and a clamp screw through each clamp, wherein the clamps comprise a protrusion, wherein the protrusion extends outside the hollow body to the open base surface over a distance A, wherein a screw head of the clamp screw rests against a support surface, the support surface being located in the flush-mounted box at a distance B from the open base surface, where the distance A is at least 70% of the distance B, where the distance B is at least 15 mm and wherein a distance between a first clamp screw and a nearest second clamp screw is at most 45 mm. The invention also relates to a kit and a method for installing an electrical base element in a hollow wall.