Installation Box Retaining Projections for Wall Mounting
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Solution Overview
Problem
Existing installation boxes struggle with effective mechanical engagement and stabilization within holes in walls, particularly in solid structures like concrete or brickwork.
Innovation Solution
The installation box features retaining projections, including retaining arms and flaps, which provide centering and secure mechanical engagement by bending elastically to fit snugly within the hole, ensuring stability and preventing displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the installation box is provided with simple projections for mechanical engagement, then the device complexity is reduced, but the mechanical engagement and retention effectiveness deteriorates
Solution Approach 1:
The retaining projection is segmented into multiple functional parts: a body portion, a retaining arm extending radially outward, and a retaining flap extending radially inward. Each segment performs a specific function - the body provides structural support, the arm engages with the hole wall for centering, and the flap provides retention by bending elastically. This segmentation resolves the contradiction by creating a complex functional structure from simpler geometric components.
Solution Approach 2:
The retaining flap is designed to be elastically deformable, allowing it to dynamically adapt during installation. When the installation box is inserted into the hole, the flap bends elastically to engage with the hole wall, then springs back to provide retention force. This dynamic behavior enables reliable mechanical engagement without requiring a complex rigid structure.
2Reliability
If the retaining flaps are made highly flexible for better engagement, then the mechanical engagement improves, but the risk of excessive bending and breakage increases
Solution Approach 1:
Different parts of the retaining projection have different flexibility characteristics. The retaining arm is relatively rigid to provide centering function, while the retaining flap is elastically deformable for engagement. The connection between these parts is designed with specific geometry to allow controlled elastic deformation. This local differentiation of mechanical properties allows the structure to achieve reliable engagement while preventing excessive bending that would cause breakage.
Solution Approach 2:
The elastic deformation capability of the retaining flap acts as a cushioning mechanism. During installation, the flap absorbs the impact and stress of engagement through elastic bending, preventing excessive forces from being transmitted to the connection point. This beforehand cushioning protects the structure from breakage while maintaining reliable mechanical engagement.
3Reliability
If the installation box is designed to fit tightly in the hole, then the retention effectiveness improves, but the adaptability to varying hole dimensions deteriorates
Solution Approach 1:
The retaining projection utilizes elastic deformation to adapt to varying hole dimensions. The degree of bending of the retaining flap changes depending on the fit between the installation box and the hole. When the hole is slightly larger, the flap bends more to engage the wall; when the fit is tighter, the flap bends less. This parameter change in deformation degree allows the same structure to achieve reliable retention across different hole sizes.
Solution Approach 2:
The retaining projection serves multiple functions simultaneously: the body provides structural support, the arm provides centering, and the flap provides retention. This multi-functionality allows a single component to adapt to varying conditions while maintaining overall effectiveness. The structure can accommodate different hole dimensions while still achieving both centering and retention functions.
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
The design ensures secure mounting and retention within varying hole dimensions, maintaining optimal positioning and preventing removal, while accommodating different hole sizes and depths.
Implementation Method 1
the retaining arms have a centering function when the side wall(s) of the hole urge the retaining arms to be bent, i.e. the retaining arms urge the installation box to be centered with respect to the hole
Implementation Method 2
the side wall(s) of the hole urge the retaining flaps to be bent upwardly, i.e. in the direction of the box mouth, wherein free ends of the retaining flaps are elastically forced against the side wall(s) of the hole, and act as barbs against removal
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
An installation box for mounting in a hole of a wall has a longitudinal axis, and comprises a side wall having an upper edge region defining a box mouth, and a lower edge region adjoining a bottom wall, wherein the side wall on its outer surface is provided with radially extending retaining projections for clamping the installation box inside the hole of the wall. The retaining projections are flexible and elastic, and comprise retaining arms and retaining flaps. The retaining arms each have a J-shaped cross-section, each retaining arm being connected to the outer surface of the side wall at one end of the retaining arm, the connection extending substantially parallel to the longitudinal axis. Each retaining arm is configured to be elastically bent relative to said connection to deform when urged to do so during the mounting of the installation box in the hole. The retaining flaps are connected to the outer surface of the side wall at one end of each retaining flap, the connection extending substantially in a circumferential direction. Each retaining flap extends in a plane transverse to the longitudinal axis, and is configured to be elastically bent relative to said connection to deform upwardly when urged to do so during the mounting of the installation box in the hole.