Folded Sheet Metal Electrical Box for Switchgear Accessibility
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Solution Overview
Problem
Existing low voltage electrical compartments face challenges with reduced accessibility for wiring and mounting due to bulky designs and numerous parts, leading to increased manufacturing costs and complex assembly, especially when juxtaposed with other compartments.
Innovation Solution
The electrical box is designed with interlocking walls made from folded sheet metal, featuring male/female forms for assembly and minimal locking means, allowing complete front-face accessibility and easy removal, with a hinged door and pre-positioning mechanisms for efficient assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional framed structures with multiple parts are used, then structural strength is ensured, but accessibility from the front face is reduced and manufacturing cost increases
Solution Approach 1:
The patent merges multiple separate structural components (frame, corner pillars, covering panels) into a single integrated envelope made from one piece of folded sheet metal. This eliminates the need for separate framing elements and corner connectors, reducing the total number of parts while maintaining structural integrity through the folding geometry itself.
Solution Approach 2:
The patent employs a thin sheet metal envelope that is folded into a three-dimensional box structure. This thin-walled folded structure provides the necessary structural strength without requiring bulky framing elements, thereby improving front face accessibility while keeping the design simple.
2Stability of the object's composition
If corner pillars and framing structures are added, then structural stability is improved, but the overall size and bulk of the compartment increases
Solution Approach 1:
The patent uses folded geometric forms in the sheet metal envelope that create structural rigidity through angular folds and creases. These folded geometries provide structural stability without requiring additional cylindrical or bulky supporting elements, maintaining a compact overall size.
3Ease of manufacture
If multiple separate components are used for the envelope, then ease of assembly is improved, but manufacturing cost and assembly time increase
Solution Approach 1:
The patent combines multiple envelope components (sides, corners, and panels) into a single pre-folded sheet metal piece. This integrated design eliminates the need for separate assembly steps involving corner connectors and frame attachment, significantly reducing assembly time while keeping the manufacturing process straightforward through die-cutting and folding operations.
4Area of stationary object
If cells are juxtaposed together, then space utilization is improved, but accessibility and removability of individual boxes are reduced
Solution Approach 1:
The patent designs the envelope as a self-contained, modular unit with a unified folded structure. This segmentation allows each box to be independently removed from juxtaposed cells without requiring disassembly of adjacent units, as the single-piece construction provides clear separation interfaces while maintaining individual accessibility.
Data Source
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AI summary
The box (C) has a parallelepiped shaped envelope comprising a bottom wall (2), lower wall (1), upper wall (5) and side walls (3, 4) and a door (6) formed by simple parts made of folded sheet. The walls and door are fitted with each other by the shapes of tab or simple recess obtained directly by flat flow of sheets. The walls are fixed with respect to each other by a locking unit formed of nut, screw and orifices. An electrical apparatus (A) is assembled and wired on the bottom wall prior to the fixation of the lower, upper and side walls and door with complete accessibility for an operator.