Flush-to-Wall Electrical Box With Adjustable Crack-Free Closure
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Solution Overview
Problem
Existing flush-to-wall electrical boxes risk breaking the plasterboard or masonry during installation and opening/closing operations and do not provide a homogeneous aesthetic appearance when installed on plasterboard walls due to visible plastic parts of different colors.
Innovation Solution
A flush-to-wall electrical box design featuring a frame with protruding net and adjustable distance mechanisms, snap-locking teeth, and a perforated lid that integrates with the wall surface to avoid cracks and ensure aesthetic harmony.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If known electrical box designs are used with visible plastic parts, then the box can be easily manufactured and installed, but the aesthetic appearance is compromised due to visible plastic parts of different colors from the wall paint
Solution Approach 1:
The patent applies color matching between the electrical box frame and the wall surface. The frame is designed to be painted or colored to match the wall, making it visually invisible when installed. This resolves the aesthetic contradiction by changing the color property of the frame to blend with the surrounding wall surface.
Solution Approach 2:
The patent introduces a wall surface as an intermediary element that covers or blends with the frame. The wall surface acts as a mediator between the visible plastic parts and the viewer, hiding the aesthetic discrepancy through color matching and surface integration.
2Strength
If known electrical box designs are used with rigid fixing structures, then the box can be securely fixed to the wall, but the risk of breaking plasterboard or masonry during installation and operation increases
Solution Approach 1:
The patent changes the mechanical parameters of the fixing system by introducing adjustable distance mechanisms and flexible mounting options. The frame can be positioned at variable distances from the wall surface, and the fixing method can be adjusted based on wall type (plasterboard or masonry), reducing stress concentration and preventing breakage while maintaining secure fixation.
Solution Approach 2:
The patent introduces dynamic adjustability in the fixing system. The frame's distance from the wall can be adjusted during installation, and the fixing structure can adapt to different wall types. This dynamic capability allows the system to optimize its fixing strength while minimizing the risk of damaging the wall during installation and operation.
3Reliability
If the electrical box is designed with a closed lid for security, then the internal components are protected, but the ability to access and modify components becomes difficult
Solution Approach 1:
The patent segments the electrical box into a fixed frame and a removable lid. The lid can be detached from the frame to access internal components while maintaining protection when closed. This segmentation allows the system to simultaneously achieve component protection through the closed lid and ease of operation through the removable design.
Solution Approach 2:
The patent introduces dynamic functionality to the lid, allowing it to transition between closed (protective) and open (accessible) states. The lid's ability to be removed and reattached provides dynamic control over component accessibility, resolving the contradiction between protection and ease of operation.
Data Source
AI summary
A flush-to-wall electrical box including: a box-like body, perimeter fixing walls, a perimeter edge; a first frame; a front closing profile that can be removably fixed to the frame. The front closing profile is equipped with a plurality of safety teeth and the first frame is equipped with a plurality of lateral flap and with a plurality of thrust flaps.