Electrical Installation Box Assembly with Self-Locking Projections
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Solution Overview
Problem
Retrofitting electrical installation boxes into existing structures is time-consuming and requires a high number of components and tools, especially when the second side of the wall is not accessible, as traditional fastening methods from the first side are inefficient.
Innovation Solution
An electrical installation box assembly featuring a fastening part with flexibly mounted projections and flange portions that engage the wall upon insertion, allowing secure fastening without additional components, using a box case to lock the projections in place and sandwich the wall for stable installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional screw fastening method is used from the first side of the wall, then the electrical installation box can be fastened to the wall, but the installation process becomes time-consuming and requires many components and tools
Solution Approach 1:
The fastening part is divided into multiple projections that can independently engage with the wall structure. Each projection acts as an independent fastening element, allowing the system to achieve reliable fastening through multiple discrete engagement points rather than requiring multiple screws and fastening operations
Solution Approach 2:
The projections are designed to automatically engage with the wall structure upon insertion of the fastening part. The spring element provides automatic tensioning that pushes the projections against the wall, creating self-fastening without requiring additional fastening operations, tools, or components from the first side of the wall
2Reliability
If traditional screw fastening method is used from the first side of the wall, then the electrical installation box can be fastened to the wall, but the number of components and tools required increases
Solution Approach 1:
Multiple fastening functions are merged into a single integrated fastening part structure. The projections, spring element, and engagement mechanisms are combined into one component that performs all fastening operations simultaneously upon insertion, eliminating the need for separate screws, washers, and fastening tools
Solution Approach 2:
The fastening part is designed as a universal component that can be inserted from the first side of the wall and perform multiple functions: the projections engage with the wall structure, the spring provides tensioning force, and the overall structure secures the electrical installation box. This single component replaces multiple specialized fastening components and tools
3Adaptability or versatility
If the electrical installation box is installed from the first side of the wall when the second side is not accessible, then the box can be installed in existing structures, but the fastening process becomes complex and time-consuming
Solution Approach 1:
Instead of requiring fastening operations from the accessible second side of the wall, the fastening mechanism is inverted to operate entirely from the first side. The fastening part is designed to be inserted from the first side, with projections that engage the wall structure from this side, and the spring element that provides automatic tensioning without requiring access to the second side
Solution Approach 2:
The spring element automatically provides tensioning force to push the projections against the wall structure upon insertion. This self-tensioning mechanism eliminates the need for manual fastening operations, tools, or access to the second side of the wall, making the retrofit installation simple and straightforward
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
Enables quick and simple retrofit installation of electrical installation boxes without additional components, ensuring secure fastening and reducing installation time and complexity.
Implementation Method 1
a spring element (not visible in the Figures) pushing the projections (13, 14) in the fastening part (10) against the wall structure (30)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An electrical installation box assembly for installation into an opening in a wall (30), comprising a fastening part (10) comprising a tubular side wall portion (11), at least one flange portion (12), and at least one flexibly mounted projection (13, 14) extending radially from the side wall portion and adapted to engage the wall in its resting position when the fastening part is inserted inside the opening in the wall such that the at least one flange portion is in contact with the wall and a box case (20), wherein an outer diameter of a side wall portion of the box case is equal to or smaller than an inner diameter of the side wall portion of the fastening part such that upon inserting the box case into the fastening part, the box case locks the at least one projection of the fastening part into its resting position.