Sheet Metal Extender Locking via Embossed Members

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Solution Overview

Problem

Existing switch box extenders for electrical outlet boxes are costly to manufacture due to traditional methods involving metal stamping, folding, and welding, with high production costs despite low raw material costs.

Innovation Solution

The extender is formed from a flat piece of sheet metal using die stamping and bending techniques to create pairs of parallel wall sections, with embossed areas and members that connect and lock the ends, allowing for efficient production and secure attachment to electrical boxes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional metal stamping, folding and welding methods are used to manufacture extenders, then the extender can be securely formed with proper structural integrity, but the manufacturing cost becomes high

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent combines multiple manufacturing operations (stamping, folding, and welding) into a single die stamping process. The die simultaneously forms the extender body, creates embossed areas, and forms integral locking members that interlock with the box, eliminating the need for separate folding and welding steps while maintaining structural integrity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The extender design includes integral locking members that are formed as part of the extender body itself during the stamping process. These locking members automatically engage with corresponding features on the electrical box, eliminating the need for separate fastening components or assembly steps

Inventive Principle:

Principle #25Self-service

2Manufacturing precision

If traditional multi-step manufacturing processes are used, then proper structural features can be created, but production efficiency decreases

Engineering Contradiction:

Improvestructural featuresVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The die is designed to pre-form all necessary structural features including the extender walls, embossed areas, and locking members in a single operation. This preliminary formation of all features during stamping eliminates the need for subsequent folding and welding operations, significantly improving production efficiency

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The extender is designed with distinct functional segments (walls, embossed areas, locking members) that are all formed simultaneously by the die. This segmentation allows each feature to be optimized for its specific function while being efficiently produced in a single manufacturing step

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS7752731B2Method of making an electrical box extender mechanical fastener

Publication Date: 2010.07.13 THOMAS & BETTS INTERNATIONAL INC

AI summary

An extender and a method for making an extender for an electrical box is provided. The extender includes: a side wall having a length with first and second ends and a width with first and second edges, wherein the side wall is configured so that the first and second ends are in contact with each other. The extender also includes: a first member extending from the first end; a first embossed area on the first end; a second member extending from the second end; and a second embossed area on the second end. The first member is bent so that it contacts the second embossed area and the second member is bent so that it contacts the first embossed area to connect the first and second ends. The extender can have a pair of tabs extending from the first edge on opposing wall sections and each tab can have a mounting screw aperture.