Junction Box Removable Perimeter Wall Plasterboard Installation
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Solution Overview
Problem
Existing junction boxes for electrical installations on plasterboard walls face difficulties in installation precision and practicality, particularly in holding the box parallel to the ground during fixing and securing corrugated tubes without mortar or screws.
Innovation Solution
A junction box design featuring removable portions with elongate slots for tie locking, a handle with resilient attachment means for one-handed operation, and perforable scorings for alternative fixing methods, allowing for simple and precise installation on plasterboard walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional junction boxes are fixed to plasterboard walls using through screws, then the box can be securely mounted, but the installation process becomes complex and requires two hands (one for holding the box, one for screwing)
Solution Approach 1:
The junction box is divided into a base structure and a removable cover, with the base structure further segmented into functional zones including a perimeter wall with removable portions. This segmentation allows the box to be installed as a complete unit using simple anchoring, while individual components can be accessed or removed as needed, simplifying the overall installation process.
Solution Approach 2:
The box incorporates pre-defined anchoring elements and frangible portions that are prepared in advance during manufacturing. The removable portions are pre-positioned and connected via frangible connections, allowing the installer to simply snap the box into place on the plasterboard wall without complex assembly steps during installation.
2Ease of operation
If the operator holds the box with one hand during fixing, then installation becomes more practical, but precision in maintaining the box parallel to the ground deteriorates
Solution Approach 1:
The box incorporates a self-aligning mechanism where the removable portions and their associated frangible connections automatically guide the corrugated tubes into proper alignment during installation. The perimeter edge with its specific geometry provides self-positioning features that ensure the box maintains correct orientation relative to the wall and ground without requiring the installer to manually adjust alignment while holding the box.
3Reliability
If corrugated tubes are locked using mortar or cement mixtures, then the tubes are securely fixed, but the installation process becomes time-consuming and messy
Solution Approach 1:
The invention replaces the chemical bonding system (mortar or cement) with a mechanical locking system. The tie element passes through openings in the perimeter edge and engages with the corrugated tube, providing secure mechanical retention. This mechanical system is much faster to install than mortar, requiring only simple insertion and tying actions rather than mixing, application, and curing time.
4Reliability
If through screws are used to fix the box to the wall, then secure mounting is achieved, but alternative fixing solutions that do not perforate the wall are needed for certain applications
Solution Approach 1:
The box is designed with multiple mounting interface options. The base structure includes features that accommodate both through-screw mounting (with fixing flanges that can receive screws) and non-perforating anchoring methods (using adhesive or mechanical anchors inserted from the front). This multi-functionality allows the same box design to be installed securely in various wall types and applications without requiring different box models.
Data Source
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AI summary
A junction box comprises a base structure that comprises a bottom wall and perimeter walls, wherein the perimeter walls comprise removable portions that extend between the bottom wall and a perimeter edge that defines an inlet mouth of the housing volume, said removable portions being arranged to close a passage configured so as to allow the passage of a flexible tube through the corresponding perimeter wall and wherein the perimeter edge comprises a shoulder provided with a plurality of through openings.