Flush-Mounted Box Mounting Aid Foam Fixation
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Solution Overview
Problem
The existing methods for installing flush-mounted boxes in masonry are time-consuming and require precise handling of plaster, limiting the number of boxes that can be installed quickly and efficiently, as the plaster must set rapidly to prevent movement during the installation process.
Innovation Solution
An assembly aid with a receiving area for mounting foam on the outer bottom side of the flush-mounted box, which prevents the foam from flowing and allows it to spread and harden between the box and the recess, providing a stable and adhesive fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plaster is used to fix flush-mounted boxes in masonry, then the boxes can be securely fixed in the recess, but the installation process becomes time-consuming and requires precise handling with limited productivity
Solution Approach 1:
The patent replaces the traditional mechanical plaster application system with a foam-based fixation system. The foam is introduced in liquid form through injection openings, expands to fill the recess, and hardens to provide secure fixation. This substitution eliminates the need for manual plaster mixing and application, significantly reducing installation time while maintaining reliable fixation.
Solution Approach 2:
The patent utilizes the expansion properties of foam (a fluid-like material) to achieve fixation. The foam is introduced in liquid state through injection openings and expands pneumatically to fill the recess and conform to the box shape, then hardens to provide mechanical support. This pneumatic expansion mechanism enables quick and easy installation without requiring precise manual handling.
2Quantity of substance
If multiple flush-mounted boxes are installed using plaster, then more sockets can be accommodated, but the installation time increases and the plaster must set rapidly limiting the number of boxes
Solution Approach 1:
The foam injection system replaces the time-consuming plaster application process. Each box can be independently and quickly fixed by injecting foam through its injection openings, eliminating the need to work within the limited setting time of plaster. This enables installation of multiple boxes in sequence without the time constraints imposed by plaster setting.
Solution Approach 2:
The foam is pre-prepared in liquid form ready for injection, eliminating the need for on-site mixing and preparation time required for plaster. The foam can be injected immediately and will expand and harden automatically, allowing installers to quickly move from one box to the next without preparation delays.
3Productivity
If plaster is applied quickly to maintain rapid setting, then the installation process remains efficient, but the plaster consistency must be precisely controlled and handling becomes more difficult
Solution Approach 1:
The foam injection system replaces manual plaster application, eliminating the need for spatulas and precise consistency control. The foam is delivered through a controlled injection mechanism that ensures proper dosing and distribution automatically, making the process easier to operate while maintaining high productivity.
Solution Approach 2:
The foam system is self-regulating in terms of consistency and application. The foam expands automatically upon contact with the recess, conforming to the space without requiring manual shaping or positioning. This self-service characteristic eliminates the need for precise handling skills required for plaster while maintaining installation speed.
4Reliability
If the flush-mounted box is fixed while plaster is setting, then secure fixation is achieved, but the box cannot move during the setting process requiring precise positioning
Solution Approach 1:
The foam expansion mechanism provides gradual and uniform fixation. As the foam expands, it gently pushes the box into its final position and conforms to the recess shape, providing fixation without requiring precise pre-positioning. The expansion process itself ensures the box is held securely as the foam hardens, eliminating the need for rigid positioning control during the initial phase.
Solution Approach 2:
The foam acts as a cushioning medium during the fixation process. Its expandable nature allows it to accommodate minor positioning variations and provides a buffer that gently secures the box in place as it hardens. This cushioning effect prevents the need for precise positioning control that would be required with rigid plaster application.
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 quick and easy installation of flush-mounted sockets by preventing the foam from flowing and allowing it to fill and harden in place, securing the box within seconds, even in rough construction conditions, and allows for efficient installation of multiple sockets.
Implementation Method 1
mounting foam can spread out from the receiving area into the recess
Implementation Method 2
providing a stable and adhesive fixation
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a mounting aid (10; 60; 80) for a flush-mounted box (20; 70), wherein the flush-mounted box (20; 70) can be installed in a recess (40), in particular in masonry (42), and wherein the flush-mounted box (20; 70) forms an interior space for receiving electrical installation devices, wherein the mounting aid (10; 60; 80) has a receiving area for mounting foam (50), wherein the receiving area is arranged on an outer bottom side of the flush-mounted box (20; 70) facing away from the interior space, and wherein the receiving area is designed such that the mounting foam (50) can spread from the receiving area into the recess (40) in order to fix the flush-mounted box (20; 70) in the recess (40).