Resilient Aperture Cover for Electrical Box Air Sealing
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Solution Overview
Problem
Electrical boxes allow undesired air flow and heat transfer due to permanent openings formed for wire and cable access, which compromises temperature control efficiency and requires additional materials and tools for sealing.
Innovation Solution
A resiliently flexible aperture cover is integrated into the electrical box assembly, molded in a two-shot process to cover access apertures, reducing air flow and simplifying installation by minimizing the need for additional tools and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If knock out openings are formed in the electrical box for wire and cable access, then electrical connections can be made, but permanent air pathways are created that compromise vapor barrier integrity and temperature control efficiency
Solution Approach 1:
The patent applies a flexible membrane or foil material to cover the knock out openings in the electrical box. This flexible barrier allows wires and cables to penetrate through it while maintaining the vapor seal, preventing air flow and heat transfer through the openings. The flexible nature of the material enables it to conform to the opening and seal around the penetrating conductors.
Solution Approach 2:
The flexible membrane acts as an intermediary element between the need for wire access and the requirement for vapor barrier integrity. It mediates by providing a sealing layer that can be penetrated by wires while maintaining the overall seal, thus resolving the conflict between accessibility and protection.
2Object-affected harmful factors
If foam sealant is used to seal knock out openings to prevent air flow, then vapor barrier integrity is maintained, but the complexity and number of materials and tools required increases
Solution Approach 1:
The flexible membrane is integrated into the electrical box assembly itself, providing the sealing function as part of the box structure. This eliminates the need for separate foam sealant applications and reduces the number of materials and tools required for installation. The membrane performs the sealing function automatically as part of the box design.
Solution Approach 2:
The patent combines the vapor barrier function with the electrical box structure by integrating the flexible membrane into the box assembly. This merging of functions eliminates the need for separate sealing materials and simplifies the overall installation process.
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
The flexible aperture covers effectively seal air pathways, maintaining the vapor barrier integrity and reducing installation complexity while allowing easy access for electrical connections.
Implementation Method 1
resiliently flexible aperture cover
Data Source
AI summary
An electrical box assembly includes an electrical box structure including an interior defined by a plurality of walls with an aperture formed through one of the walls for providing access to the interior of the box structure. An aperture cover extends over the aperture. The aperture is formed from a resiliently flexible material and includes a slit forming feature for prescribing a location of a slit for selectively providing access to the interior of the electrical box structure. The resiliency of the aperture cover urges the aperture cover to a closed position of the slit to minimize air passage through the aperture cover.