Pop-up Cover Box Kit Front Access Wiring
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Solution Overview
Problem
The installation of electrical receptacles in conventional boxes requires disassembly, which is laborious and time-consuming, incurring high costs due to electrician hourly rates.
Innovation Solution
A pop-up cover and box kit that allows for easy installation of electrical components from the front, eliminating the need to dismantle the hinge mechanism, with features like a spring clip for secure mounting and a front opening for wire access, enabling quick connection of receptacles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional box disassembly is used to install electrical receptacles, then proper wiring connection can be achieved, but installation time and labor cost increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-attaching the wiring leads to the electrical box before the box is installed in the structure. The leads are extended through the front opening of the box, so that when the box is mounted, the wiring is already in position and ready for connection to the receptacle. This eliminates the need to disassemble the box later for wiring access, significantly reducing installation time while maintaining proper wiring connection.
2Ease of manufacture
If conventional box disassembly is used to access wiring, then receptacle connection can be made, but labor cost increases due to electrician hourly rates
Solution Approach 1:
The wiring leads are pre-positioned and extended through the front opening of the electrical box during manufacturing or pre-installation preparation. This preliminary action allows the receptacle to be connected directly to the exposed leads without requiring box disassembly, thereby improving installation efficiency and reducing the need for skilled labor hours.
3Ease of operation
If complete box removal is required for receptacle replacement, then proper wiring access is achieved, but installation complexity and time increase
Solution Approach 1:
The patent segments the wiring access function from the box structure itself by providing a dedicated front opening that is separate from the main box enclosure. The wiring leads are routed through this opening, allowing wiring access to be obtained without removing or disassembling the box. This segmentation simplifies the installation process by separating the wiring access requirement from the box removal operation.
Solution Approach 2:
The wiring leads are pre-routed and extended through the front opening of the box, so that when installation time comes, the wiring is already accessible from the front. This preliminary preparation of the wiring path eliminates the need for complex box disassembly operations during receptacle replacement.
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
Facilitates quicker and more cost-effective installation of electrical devices by allowing front access, reducing installation time and preventing damage or trip hazards while meeting safety standards.
Implementation Method 1
A spring clip holds box securely against the surface when the screws are tightened
Data Source
AI summary
A pop-up cover with a front insertable outlet. The pop-up cover includes sidewalls, a front panel, an outlet bracket, a lid defining a cavity within the cover, and an opening into the cavity. An outlet bracket enables straight-in insertion and securement of an electrical outlet within the cavity. A cover biasing and latching arrangement enables movement of the pop-up cover from a closed position to an open position. A recessed wall with an aperture on the cover enables easy replacement of the electrical outlet when needed. The cover biasing arrangement includes a pivot pin and a spring on the pivot pin biasing the cover to the open position. A thumb slide enables releasing the cover from the closed position to the open position. An alignment tab on the recessed wall enables rapid alignment and fitting of the outlet bracket to the pop-up cover.