Removable Handle Junction Box for Plasterboard Installation
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Solution Overview
Problem
Existing junction boxes are difficult to install on walls, particularly on plasterboard surfaces, due to challenges in holding the box parallel to the ground and securing it accurately, as users must hold the box with one hand and use a screwdriver with the other.
Innovation Solution
A junction box with a removable handle that can be easily grasped during installation, featuring interlocking coupling means on the rear wall and perimeter, allowing one-handed operation, and multiple fixing options, including breakable portions and cable ties, for secure attachment to plasterboard walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the junction box is fixed to the wall using conventional methods, then the box can be securely attached, but it becomes difficult to hold the box in the correct position parallel to the ground during installation
Solution Approach 1:
The coupling means is divided into two separate components: a first coupling means integrated into the wall plate and a second coupling means integrated into the junction box. This segmentation allows the box to be easily positioned and held against the wall using the interlocking coupling means before final fixation, resolving the contradiction between secure attachment and ease of positioning.
Solution Approach 2:
The coupling means acts as an intermediary mechanism between the wall plate and the junction box. It provides a temporary but stable connection that facilitates easy positioning and holding of the box during installation, while ultimately enabling secure attachment when engaged.
2Reliability
If the user holds the box with one hand and uses a screwdriver with the other, then the box can be fixed to the wall, but the installation process becomes cumbersome and difficult
Solution Approach 1:
The fixation process is segmented into two distinct phases: first, the coupling means provides immediate mechanical interlocking for stable positioning; second, the breaking action secures the box permanently. This eliminates the need for simultaneous hand operations during the critical positioning phase, making installation much easier.
Solution Approach 2:
The coupling means is designed to be engaged before final fixation, performing the preliminary action of securing the box in position. This preliminary stabilization allows the installer to work comfortably without needing to continuously hold the box, significantly improving ease of operation during the fixation process.
3Ease of operation
If the handle is permanently fixed to the junction box, then it can always be used for handling, but it obstructs the insertion of cables and wiring when not needed
Solution Approach 1:
The handle's position is made dynamic rather than fixed. It can be relocated from a position that might obstruct cable insertion to a position where it does not interfere, or removed entirely when not needed. This dynamic adaptability resolves the contradiction between maintaining handling capability and ensuring cable insertion accessibility.
Solution Approach 2:
The handle is designed as a separate, removable component rather than an integrated permanent feature. This segmentation allows the handle to be detached or repositioned when cable insertion is required, providing flexibility to adapt to different installation scenarios while maintaining ease of handling when the handle is in place.
4Ease of operation
If the handle is made removable with interlocking coupling means, then it can be easily attached and removed, but the structure becomes more complex
Solution Approach 1:
The coupling means is designed with a simple breaking action for the first coupling means, creating a disposable or single-use feature that simplifies the overall structure. This approach reduces complexity compared to fully reversible mechanical couplings, while still achieving easy attachment and removal of the handle.
Solution Approach 2:
The coupling system is segmented into two distinct mechanisms: a reversible interlocking coupling for easy handle attachment/removal, and a breaking coupling for permanent fixation. This segmentation allows each component to be optimized for its specific function, keeping the overall structure manageable despite the added versatility.
Data Source
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AI summary
A junction box comprises a base structure adapted for defining a housing volume and that comprises a bottom wall, perimeter walls, a handle removably connected to the base structure and first and second fastening means of the handle, wherein the first and the second fastening means are configured so as to removably hold the handle at a central portion of the base structure or at a peripheral portion thereof, respectively.