Flush-Mounted Electrical Box With Screw Appendage Panel Fixing
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Solution Overview
Problem
Existing flush-mounted boxes for electrical systems face inefficiencies in fixing to panel walls, requiring complex adjustments and cuts, and are not versatile for different panel types and thicknesses.
Innovation Solution
A flush-mounted box design with protruding appendages and screw abutments that allow reversible attachment to panel openings, enabling quick and stable fixation on various panel sizes and types without external flanging, using screw tightening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cable tie systems with serrated tabs are used to retain the box between panel faces, then the box can be fixed to the panel, but the tabs must be cut after installation which reduces productivity and increases loss of time
Solution Approach 1:
The invention extracts the cutting operation from the installation process by using a screw mechanism that secures the box without requiring tabs to be cut. The screw thread engages with the panel and the box body, providing secure retention while eliminating the need for post-installation cutting of cable ties.
Solution Approach 2:
The invention replaces the mechanical cable tie system with a screw-based fastening mechanism. Instead of using serrated tabs that require cutting, the screw provides continuous threaded engagement that secures the box reliably without requiring any cutting operations.
2Adaptability or versatility
If a clamp system with adjustment for different panel thicknesses is provided, then the box can be adapted to different panel thicknesses, but the guide system becomes relatively complex increasing device complexity
Solution Approach 1:
The invention makes the appendage dynamic by allowing it to protrude or retract within the box body. This dynamic configuration enables the appendage to adapt to different panel thicknesses without requiring a complex adjustable guide system. The appendage can be positioned at different protrusion levels to accommodate various panel depths.
Solution Approach 2:
The invention performs preliminary action by providing multiple predetermined positions for the appendage within the box body. These pre-configured positions allow the appendage to be set at the appropriate protrusion level before installation, eliminating the need for complex adjustments during installation while maintaining adaptability to different panel thicknesses.
3Strength
If the perimeter wall has external perimeter flanging at the free edge, then the box structure is more robust, but the box cannot be inserted frontally into the opening making ease of operation worse
Solution Approach 1:
The invention segments the box structure by separating the perimeter wall from the free edge. The perimeter wall maintains its structural integrity while the free edge is kept clear without flanging. This segmentation allows the box to be inserted frontally into the opening while the perimeter wall provides the necessary structural support through the appendage retention mechanism.
Data Source
Figure 1~1a
Figure 2~3
Figure 4
AI summary
A flush-mounted box (1) for electrical systems intended for installation on panel walls, comprises a box-like body (2) that includes a perimeter wall (3) having a free front edge (5) opposed to a bottom edge (4), in said perimeter wall (3) there being provided at least one opening (9, 10). The flush-mounted box (1) further comprises at least one appendage (20) configured to be partially inserted into the opening (9, 10) and to protrude reversibly through it. There is also provided a front abutment (25A) to retain the box on the panel (26). The perimeter wall (3) of said box (1) is devoid of external perimeter flanging at said free edge (5), and the front abutment (25A) includes a screw (24) with enlarged head (25) fixable to the appendage (20).