Installation Box Recess for Flush Mounting Electrical Devices
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Solution Overview
Problem
Existing installation boxes struggle to accommodate electrical installation devices for flush mounting without requiring extensive modifications to the mounting surface, as the cylindrical compartment dimensions often mismatch with the installation device, making it difficult to achieve a flush installation without damaging the board.
Innovation Solution
The installation box features a proximal end part with a recess larger than the external diameter of the cylindrical compartment, allowing for flush mounting by cutting a larger hole in the board, and includes a polygonal shape with reduced thickness for easy removal and adjustment, enabling the use of existing magnetic locators and hole saws for precise drilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the installation box uses a cylindrical compartment with fixed dimensions, then it is easy to locate and drill using magnetic locators and hole saws, but it cannot accommodate flush mounting devices that require larger opening dimensions
Solution Approach 1:
The installation box is divided into two distinct parts: a cylindrical mounting compartment for locating and drilling operations, and a polygonal recess area for accommodating the installation device. This segmentation allows each part to serve its specific function optimally - the cylindrical part maintains compatibility with existing tools while the polygonal recess provides the necessary space for flush mounting devices
Solution Approach 2:
The polygonal recess is nested within the cylindrical compartment structure. The recess has dimensions larger than the external diameter of the cylindrical compartment in certain directions, allowing the installation device to extend beyond the cylindrical boundary while still being anchored by the cylindrical mounting portion. This nested configuration enables both locating accuracy and device accommodation
2Object-affected harmful factors
If the installation box accommodates a larger portion of the device for flush mounting, then aesthetic appearance improves and damage risk reduces, but it requires a larger opening in the board which may damage existing installations
Solution Approach 1:
The installation box is pre-configured with the polygonal recess and cylindrical compartment structure before installation. The breaking lines are pre-formed in the material, allowing the larger opening to be created by simply breaking along these lines rather than cutting through the entire board. This preliminary preparation makes the larger opening process simple and damage-free
Solution Approach 2:
The installation box structure varies locally - the cylindrical compartment maintains a smaller diameter for precise locating, while the polygonal recess extends outward to provide the larger opening needed for flush mounting. This local variation in dimensions allows the board opening to be larger where needed while maintaining precision where required
3Adaptability or versatility
If the installation box uses a circular perimeter, then existing magnetic locators and hole saws can be used, but it cannot provide the larger opening dimensions needed for flush mounting devices
Solution Approach 1:
The opening structure is segmented into a circular cylindrical compartment for tool compatibility and a polygonal recess for adequate device accommodation. The circular perimeter of the cylindrical compartment ensures compatibility with existing magnetic locators and hole saws, while the polygonal recess extends beyond this circle to provide the necessary larger opening dimensions
Data Source
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AI summary
An installation box (1) for accommodating an electrical installation device, the installation box comprising a distal end part having an essentially cylindrical compartment (5) adapted for accommodating at least partially said electrical installation device, where the compartment has predetermined internal and external diameters, wherein an proximal end part (9) of said cylindrical compartment (5) comprises a proximal end surface (10) and a recess (11) in said end surface (11) for accommodating said electrical installation device, said recess (11) having dimensions across said end surface (10), which are larger than said external diameter of the of the cylindrical compartment (5).