Electrical Housing Knockout Edge That Contains Sharp Web Residue
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Solution Overview
Problem
Existing housings for electrical installations have sharp-edged residues after cutting breakout elements, which can damage cables or cause injuries during installation.
Innovation Solution
The housing design features a bulge in the edge of the opening where the web is fastened, allowing the web residue to remain inside the bulge after separation, preventing contact with cables or installers' fingers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the web is cut to separate the breakout element from the housing wall, then the breakout element can be removed, but sharp-edged residues remain that can damage cables or cause injuries
Solution Approach 1:
The patent applies local quality by creating a bulge with different geometric properties than the surrounding wall. The bulge has a curved inner surface that specifically captures and contains the sharp web residues, while the rest of the housing wall maintains its original structure. This localized geometric modification ensures that harmful sharp edges are contained in a safe region without affecting the overall housing structure or cable routing paths.
Solution Approach 2:
The patent converts the harmful sharp-edged web residues into a beneficial feature by having them become the forming tool for the bulge itself. When the web is cut and removed, its sharp edges naturally create the bulge geometry, and these same edges then serve to contain other sharp residues within the bulge cavity. The harmful sharp edges are thus transformed into a protective structural feature.
2Device complexity
If the edge of the opening is formed parallel to the outer contour of the breakout element, then the structure is simple, but sharp-edged residues remain exposed after web separation
Solution Approach 1:
The patent introduces a localized geometric feature (the bulge) at specific positions along the opening edge where webs are attached. This bulge creates a three-dimensional cavity that captures sharp web residues, while the rest of the opening edge maintains a simple planar geometry. The solution adds minimal complexity only where needed to solve the harmful residue problem.
Solution Approach 2:
The patent transitions from a two-dimensional planar opening edge to a three-dimensional structure by adding the bulge. This dimensional change creates depth and volume, allowing the formation of a cavity within the bulge that can contain sharp residues. The bulge protrudes from the plane of the housing wall, creating a safe zone that captures harmful edges without significantly complicating the overall simple structure.
Data Source
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AI summary
A housing encloses a receiving chamber defined by walls, a knock-out element, held in an aperture by means of connecting portions, being provided in one of the walls. The edge of the aperture has a concavity in the region of the connecting portions.