Old Work Box Breakaway Wing Structure for Single-Piece Molding
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Solution Overview
Problem
Existing non-metallic old work boxes, typically made of plastic, require separate injection molding and assembly of multiple parts, which is time-consuming and labor-intensive.
Innovation Solution
The old work box design incorporates molded-in wings with runners that allow for a single-piece formation during molding, eliminating the need for separate assembly by enabling the wings to move and break upon installation, facilitating secure affixation to a wall.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple parts are separately injection molded and assembled, then manufacturing flexibility and part quality are improved, but assembly time and labor intensity increase
Solution Approach 1:
The patent combines multiple separately molded parts (partition, wings, and runners) into a single integrated old work box component. The partition includes integrally formed wings with breakable runners that are molded as one piece, eliminating the need for separate assembly operations and reducing labor intensity while maintaining manufacturing flexibility through the injection molding process
2Strength
If wings are permanently attached to the partition, then structural integrity is improved, but ease of installation and wall affixation are worsened
Solution Approach 1:
The patent incorporates breakable runners as integral parts of the wings during the molding process. These runners are pre-configured to break at a predetermined location during installation, allowing the wings to be initially positioned and then secured to the wall. This preliminary integration maintains structural integrity while enabling easy installation through controlled breakage
Solution Approach 2:
The patent changes the structural parameter of the runner from permanent to breakable by designing it with a predetermined break point. The runner transitions from a continuous rigid structure to a segmented structure that can fracture under controlled conditions, enabling the wing to move from a fixed state during molding to a movable state during installation, then to a secured state after wall attachment
Data Source
AI summary
An old work box for installation in a wall includes: a partition having a partition outer surface and a partition inner surface; a backing wall attached to the partition, the backing wall and the partition forming a work box cavity; at least one flange disposed on the partition; a first wing movably disposed on the partition; and a first runner connecting the first wing to the partition outer surface and that breaks upon movement of the first wing.