Variable-Height Installation Box With Outward-Folding Support Strips
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Solution Overview
Problem
Existing installation boxes with variable heights face disadvantages such as reduced interior space due to deformable or adjustable components that consume space, limiting their ability to accommodate wiring and installation units effectively at different depths.
Innovation Solution
An installation box with a deformable lower side wall portion featuring flexible support strips that remain extended at normal forces and fold when a predetermined compressive force is exceeded, allowing continuous adjustment between maximum and minimum heights without reducing interior volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the lower side wall portion is made deformable to adjust box height, then the installation box can fit different wall depths, but the deformable components consume interior space reducing the volume available for wiring and installation units
Solution Approach 1:
The lower side wall portion is segmented into multiple vertical elements (wall sections) that can independently fold or collapse. This segmentation allows the wall to compress vertically without the horizontal space-consuming components found in prior art, maintaining interior volume while reducing overall height to fit different wall depths.
Solution Approach 2:
The lower side wall portion is designed as a dynamic structure that can change its vertical dimension on demand. The wall sections can transition between extended and folded states, allowing the box height to adapt to different installation requirements while the folded sections occupy minimal space and do not encroach on the interior volume available for wiring and installation units.
2Reliability
If the bottom portion tapers towards the bottom plate to provide snapping function, then the box can be securely mounted, but the interior space is reduced and cannot be fully used for electric wiring and switch units
Solution Approach 1:
The snapping function is extracted from the bottom portion structure and implemented as a separate mounting mechanism. The bottom portions are designed to be substantially parallel to each other, maximizing interior space, while the mounting security is provided by engagement features that snap into the wall structure without requiring tapered bottom portions that would consume valuable interior volume.
Solution Approach 2:
Instead of using vertical tapering of the bottom portion to achieve mounting security, the invention uses horizontal engagement features that extend outward from the side walls. This dimensional shift allows the mounting function to be achieved without sacrificing vertical interior space, as the engagement occurs in the radial direction rather than consuming axial height.
3Ease of operation
If a first circumferential strip extends radially inward to provide snapping function, then the box can be positioned correctly, but the strip blocks considerable space within the box that cannot be used for electric wiring
Solution Approach 1:
The positioning and snapping functions are extracted from the interior space and implemented as external features on the side walls. The engagement features are positioned on the outer surface of the installation box, allowing them to interact with the wall structure without encroaching on the interior volume needed for electric wiring and installation units.
Solution Approach 2:
The side walls are designed with flexible or deformable regions that can elastically deform during insertion and mounting. This flexibility allows the walls to expand or contract slightly to engage with the wall structure, providing positioning accuracy and secure mounting without requiring rigid internal support structures that would consume interior space.
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
The solution enables the installation box to maintain maximum interior volume and accommodate various wall depths, ensuring effective use of space for wiring and installation material by folding the support strips outwardly, thus optimizing dimensions and volume at different heights.
Implementation Method 1
each support strip is configured to remain in the extended state under a compressive force exerted in a direction along the longitudinal axis when said force is less than or equal to a predetermined force, and to fold outwardly from the extended state to the folded state along a folding line located between the second upper edge region and the second lower edge region and extending transverse to the longitudinal axis of the installation box, when said compressive force exceeds said predetermined force
Data Source
Figure 1~2
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Figure 5~7
AI summary
An installation box for mounting in a hole of a wall has a longitudinal axis, and comprises: a rigid cylindrical upper side wall portion having a first upper edge region defining a box mouth, and a first lower edge region; a deformable cylindrical lower side wall portion having a second upper edge region adjoining the first lower edge region, and a second lower edge region; and a circular bottom wall adjoining the second lower edge region. The lower side wall portion comprises: a plurality of support strips spaced along the circumference of the lower side wall portion, each support strip extending between the second upper edge region and the second lower edge region in the direction of the longitudinal axis; and a plurality of lower side wall parts made from a flexible material, each extending between two adjacent support strips and between the second upper edge region and the second lower edge region. Each support strip is configured to remain in an extended state under a compressive force exerted in a direction along the longitudinal axis of the installation box when said force is less than or equal to a predetermined force, and to fold outwardly from the extended state to a folded state when said force exceeds said predetermined force.