Spoutless Electrical Box with Adjustable Mounting Ring
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Solution Overview
Problem
Existing flush-type boxes for electric wirings face issues with permanent oblique orientation due to fixed nut member orientation, leading to askew positioning of components and cover plates under force, and current solutions either require complex measures or allow orientation changes post-wiring.
Innovation Solution
A spoutless box design with a mounting ring that allows adjustable attachment, featuring radially facing surfaces and teeth for precise angle setting, enabling the electrical fitter to set the mounting ring's position to compensate for oblique angles up to 90 degrees, ensuring secure and correct orientation of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If nut members are integrally formed or inlaid in the box edge, then the attachment structure is simplified, but the orientation of components becomes fixed and askew positioning cannot be corrected
Solution Approach 1:
The attachment structure is divided into two separate components: the box with integrated nut members and a separate mounting ring with screw holes. This segmentation allows the mounting ring to be rotated independently to correct orientation while keeping the box structure simple.
Solution Approach 2:
The mounting ring acts as an intermediary element between the box and the components. It receives the screw forces from components and transfers them to the box through its peripheral engagement, allowing orientation correction without modifying the box structure.
2Adaptability or versatility
If a rotatable mounting ring is used to correct orientation, then orientation can be adjusted, but the ring can rotate during use causing components to become askew again
Solution Approach 1:
The mounting ring is preliminarily positioned and oriented correctly during installation, and then fixed in place by tightening screws into the nut members. This preliminary positioning ensures correct orientation before final fixation prevents any subsequent rotation.
Solution Approach 2:
The stability of the mounting ring is changed from a variable state (rotatable during installation) to a fixed state (secured by tightened screws). The parameter of rotational freedom is transformed from useful during installation to harmful during use, and is controlled by the tightening force of the screws.
3Ease of manufacture
If the box is manufactured by injection moulding with integrated nut members, then manufacturing is simplified, but special measures are required and the orientation is always the same
Solution Approach 1:
The manufacturing process is segmented into two independent steps: first, the box is injection moulded with integrated nut members (simple and efficient); second, a separate mounting ring is attached to the box edge (allows orientation flexibility). This segmentation maintains manufacturing simplicity while adding adaptability.
Solution Approach 2:
The mounting ring serves multiple functions: it provides screw attachment points for components, enables orientation adjustment during installation, and ensures stable fixation during use. This multi-functionality is achieved without complicating the box manufacturing process.
Data Source
Figure 1A~3
Figure 2
Figure 4A~4B
AI summary
Assembly of spoutless box for electric wirings, to be placed in a hole in a wall of a building, comprising a bottom wall and a circumferential wall extending circular around a centre line of the box, which define an inner space for accommodating switch- and/or connection components for the electric wiring, wherein the circumferential wall of the box is provided with at least one hole, optionally provided with a break-out partition for passage of electric wires that are optionally enveloped by a wiring pipe, wherein the assembly further comprises a mounting ring having means for attaching the components, wherein the box at the side facing away from the bottom wall is provided with an opening to the inside of the box, which opening is limited by an edge of the circumferential wall, wherein the mounting ring and the edge are provided with first and second connection means, respectively, for connecting the mounting ring with the edge, wherein the first and second connection means are provided with first and second means, respectively, for fixing the mounting ring at the edge in a chosen orientation of the attachment means at the mounting ring in which they take an oblique angle to the centre line of the hole.