Rotatable Wing Sconce Box for Shallow Wall Cavities
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Solution Overview
Problem
Conventional sconce boxes require significant disruption and increased installation time and cost when mounting in areas with shallow wall cavities due to obstructions like pipes, as they are designed for standard 2×4-inch studs and 3.5-inch cavities, making it difficult to secure lights in old work situations without removing wallboard and rerouting piping.
Innovation Solution
A sconce box assembly with rotatable wings that can be retracted for insertion through a hole in the wall and extended to clamp securely, accommodating various wallboard thicknesses and shallow cavities without disrupting the surrounding wall, allowing for quick and cost-effective installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional sconce box is used in a shallow wall cavity, then the mounting depth is insufficient, but the installation requires removing wallboard and rerouting piping
Solution Approach 1:
The sconce box incorporates rotatable wings that can transition between retracted and extended positions. During installation, the wings are retracted to allow the box to pass through the wall opening, then extended and tightened to clamp the box securely to the wallboard from the front side, eliminating the need for deep wall cavities or rear-side fastening
Solution Approach 2:
The mounting mechanism is divided into separate functional components: the electrical box body and the rotatable wings. This segmentation allows the wings to be independently positioned and adjusted, enabling the box to be installed from the front side of the wall without requiring access to the wall cavity or structural studs
2Volume of stationary object
If the wall cavity is reduced by interior piping, then the available mounting space is limited, but the installation time and cost increase
Solution Approach 1:
The rotatable wings provide a dynamic mounting solution that adapts to limited wall cavity space. By rotating the wings into the extended position, the box clamps to the wallboard surface, requiring no rear-side clearance and allowing installation in front-of-wall scenarios where piping occupies the wall cavity
Solution Approach 2:
The rotatable wings act as an intermediary mechanism between the electrical box and the wallboard. This intermediary allows the box to be securely mounted to the wallboard surface without requiring access to or clearance within the wall cavity, where piping obstructions exist
3Adaptability or versatility
If different wallboard thicknesses are accommodated, then the mounting versatility increases, but the number of SKUs increases
Solution Approach 1:
The rotatable wings are designed with adjustable positioning capabilities that allow a single electrical box model to accommodate multiple wallboard thicknesses. The wings can be positioned at different angles and tightness levels, providing universal compatibility across various wallboard specifications without requiring different box models
Data Source
AI summary
A sconce box assembly for mounting sconces on walls of various wallboard thicknesses and shallow wall cavities with no disruption to the surrounding wall. The sconce box assembly includes an electrical box having a sidewall, a back wall, an electrical cavity, and wing bosses extending from the sidewall. First rotatable wings secured to the wing bosses are adapted for rotation between a retracted position, in which the rotatable wings are positioned inside the sidewall perimeter, and an extended position in which the rotatable wings are positioned outside the sidewall perimeter. Retracting the wings facilitates insertion of the electrical box through a hole in a wall. Extending the wings facilitates tightening the wings and clamping the electrical box to the wallboard. The invention contemplates at least one second rotatable wing that may be used optionally in place of the first rotatable wing in order to accommodate attachment to various thicknesses of wallboards.