Electrical Box Knock-Out Tool with Pivot Engagement
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Solution Overview
Problem
Existing tools fail to efficiently remove knock-outs from electrical boxes without breaking some of the webs connecting them to the box, leading to incomplete removal and requiring additional force to fully detach the knock-outs.
Innovation Solution
A tool with a handle and angled shaft featuring indentations for engaging the box edge, a hook with notches, and a tapered slot at the distal end to securely grasp and break the remaining web, allowing for complete removal of knock-outs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an installer uses moderate force to remove a knock-out from an electrical box, then the knock-out can be removed without excessive effort, but the webs connecting the knock-out to the box wall often break incompletely, causing the knock-out to hang from the box
Solution Approach 1:
The tool is divided into distinct functional segments: a pivot engagement feature that interfaces with the box wall, a shaft that transmits force, and a knock-out engagement feature with a slot and groove that interfaces with the knock-out. This segmentation allows each part to perform its specific function optimally, ensuring complete removal without web breakage.
Solution Approach 2:
The tool acts as an intermediary between the installer and the knock-out. By introducing this intermediate device with its specific geometry (slot, groove, pivot point), the installer can apply force effectively while the tool ensures complete separation of the knock-out from the box wall, preventing incomplete removal.
2Reliability
If an installer applies excessive force to remove a knock-out that is hanging from the box by a web, then the knock-out can be fully removed, but additional effort and time are required
Solution Approach 1:
The tool's geometry is designed to perform preliminary actions in sequence: first engaging the pivot point on the box wall, then engaging the knock-out through the slot and groove, and finally applying force to break all webs simultaneously. This preliminary positioning and engagement sequence ensures complete removal in a single action, preventing the need for additional forceful maneuvers.
3Reliability
If the tool includes a pivot point engagement feature and a knock-out engagement feature with specific geometry, then the tool can effectively remove knock-outs without breaking webs, but the device complexity increases
Solution Approach 1:
Multiple functional features (pivot engagement, force transmission shaft, knock-out engagement with slot and groove) are merged into a single integrated tool body. This consolidation achieves reliable knock-out removal without requiring multiple separate tools or complex assembly mechanisms, balancing functionality with simplicity.
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 the user to effectively break and remove knock-outs from electrical boxes by providing a pivot point and a mechanism to engage and detach the knock-outs from the box, reducing the effort required and preventing web breakage during removal.
Implementation Method 1
The tool includes an elongate member having a proximal end and a distal end. The elongate member has an angle between the proximal end and the distal end.
Implementation Method 2
The distal end includes a hook portion. The hook portion includes a slot at the second end and a groove at a bend of the hook. A first notch is located on the elongate member.
Data Source
AI summary
The invention disclosed is a tool for the removal of knock-outs from electrical boxes. The tool may include a handle connected to an elongate member such as a rod, the elongate member having a bend between the handle and a termina end that is bent back or forms a hook. The terminal end may include a flattened end and a slot opened at the end to allow the user to engage the edge of a knock-out. The tool may also include a groove in the radius or bend of the hook, also to allow the user to engage the edge of a knock-out. The tool also includes notches on the elongate member to allow the user to engage the edge of a an electrical box to manipulate or rotate the tool about the engagement to dislodge or displace the knock-out from the electrical box with the tip of the terminal end.