Threaded Fastening Sleeve for Insulation-Mounted Electrical Boxes
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Solution Overview
Problem
Existing fastening devices for installing electrical boxes in wall insulation require attachment to the underlying wall before insulation application, risking damage and limiting flexibility in selecting or replacing installation boxes.
Innovation Solution
A fastening sleeve with a thread-like profile on its outer surface, allowing secure screwing into a wall, including insulation layers, and accommodating various installation boxes by providing a cylindrical opening and locking mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fastening devices are attached to the underlying wall before insulation application, then the fastening devices can be securely mounted, but they risk damage during insulation application and limit flexibility in selecting or replacing installation boxes
Solution Approach 1:
The fastening system is divided into two independent components: the fastening sleeve (which remains in the wall) and the installation box (which can be freely selected and replaced). This segmentation allows the mounting structure to be established first for reliability, while the installation box can later be changed without affecting the mounted component.
Solution Approach 2:
The installation box is extracted from the integrated fastening device and made as a separate, removable component. The fastening sleeve provides the mounting function while the installation box can be independently selected, removed, and replaced, solving the contradiction between secure mounting and flexibility.
2Reliability
If fastening devices are attached to the underlying wall before insulation application, then the fastening devices can be securely mounted, but they are at risk of damage during insulation application
Solution Approach 1:
The fastening sleeve is designed to be inserted into the wall opening after insulation application, with the collar section resting on the outer surface of the insulation. This preliminary design of the insertion path and collar positioning prevents damage during insulation application while ensuring secure mounting.
Solution Approach 2:
The collar section acts as an intermediary element that rests on the insulation surface, distributing forces and protecting the fastening sleeve from damage during insulation application. It serves as a buffer between the fastening device and the insulation material.
3Strength
If a thread-like profile is provided on the outer surface of the wall section, then the fastening sleeve can be securely fastened to the wall with high pull-out forces, but the manufacturing complexity increases
Solution Approach 1:
The thread-like profile is integrated directly into the wall section of the fastening sleeve as a unified structure, combining the fastening function with the body of the component. This merging allows the threaded feature to be formed during the same injection molding process, increasing pull-out strength without significantly increasing manufacturing complexity.
Solution Approach 2:
The thread-like profile is formed by modifying the geometry parameters of the wall section during injection molding. By changing the mold cavity design to include threading features, the fastening capability is enhanced while using the same basic manufacturing process, minimizing the increase in manufacturing complexity.
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
Enables easy and secure insertion of the fastening sleeve into a wall, including insulation layers, with high pull-out forces and flexibility in choosing or replacing installation boxes, facilitating efficient electrical installations.
Implementation Method 1
a thread-like profile is provided on an outer surface of the wall section, at least in some areas... the fastening sleeve can be screwed into an opening in a wall... When screwed in, the collar section rests on the outer surface of the insulation and forms an end stop for the rotation of the fastening sleeve. Since the thread-like profile engages with the wall material when screwed in, this ensures that the fastening sleeve is fixed in the opening and secured against being pulled out
Data Source
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AI summary
The invention relates to a fastening sleeve (1) for screwing into a wall, in particular into an insulation layer, and for receiving an installation box (100) for an electrical installation, wherein the fastening sleeve (1) has a hollow cylindrical wall section (2) formed by a wall and a collar section (20) extending radially outward at a first end (5) of the wall section (2). The fastening sleeve according to the invention is characterized in that a thread-like profile (7) is provided on an outer surface (3) of the wall section (2), at least in some regions.