Rough-in box for high wall minisplit (ductless) airconditioners
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Solution Overview
Problem
Existing rough-in boxes for mini-split air conditioner systems are expensive, not suitable for 6 inch wall thicknesses at 24 inch stud centers, and are bulky, leading to high storage and transportation costs, while also being prone to damage during construction due to their design limitations.
Innovation Solution
A foldable rough-in box with score marks for configuration into a 3-sided shape, featuring a raised frame for sheetrock alignment, reversible design for easy installation, and adjustable mounting brackets for various stud spacings, along with a removable protective cap for the drain fitting to prevent debris entry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rigid rough-in boxes are used, then structural strength and durability are improved, but storage and transportation costs increase due to bulky design
Solution Approach 1:
The rough-in box is divided into multiple flat panels that can be folded together to form the three-dimensional structure. This segmentation allows the box to be collapsed into a flat state for compact storage and transportation, while maintaining full structural integrity when assembled and used.
Solution Approach 2:
The box transitions from a static rigid structure to a dynamic foldable structure. The flat panels are connected in a way that allows them to fold and unfold, enabling the box to change its volume significantly between storage and usage states while maintaining structural strength during installation and use.
2Reliability
If pre-piped and prewired rough-in boxes are installed early, then service connections are protected from damage, but flexibility in accommodating different wall thicknesses is reduced
Solution Approach 1:
The adjustable leg mechanism allows the box to dynamically adapt its height and position to accommodate different wall thicknesses and stud spacings. The legs can be extended or repositioned to ensure the box protrudes correctly from various wall configurations, providing versatility while maintaining protection of service connections.
Solution Approach 2:
The box is pre-piped and prewired during manufacturing, allowing service connections to be made before the final installation position is determined. This preliminary preparation protects the service connections from damage during construction while the adjustable features enable adaptation to specific wall configurations during installation.
3Ease of manufacture
If flat panels are used to reduce material cost, then manufacturing cost decreases, but structural stability during assembly may be compromised
Solution Approach 1:
The box is constructed from multiple flat panels connected together, which simplifies manufacturing compared to molding a complete three-dimensional box. The segmented design reduces material costs and manufacturing complexity while the connection mechanisms ensure structural stability when assembled.
Solution Approach 2:
The flat panels are folded and connected to form a three-dimensional box structure with rigid angles and joints. This folding action transforms two-dimensional flat panels into a stable three-dimensional configuration that maintains structural integrity during assembly and use.
Data Source
AI summary
An evaporator rough-in box includes a flat panel having a first score mark by which the flat panel can be folded between a front wall and a top wall of the rough-in box, and a second score mark by which the flat panel can be folded between the front wall and a bottom wall of the rough-in box. The front wall has an opening through which an interior of the rough-in box can be accessed, the opening being covered by a removable cover plate. Left and right ends of the top and bottom walls include extension pieces bendably attached to central portions of the top and bottom walls to form mounting brackets. The central portions include score marks that delineate knock-out holes by which a lineset and a drain line can be installed to the rough-in box. A drain fitting is attached to the knock-out hole of the drain line.