Adjustable Mullion Receptacle with Two-Faced Safety Block
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Solution Overview
Problem
Conventional mullion receptacles and sill blocks pose challenges such as being difficult to remove and reinstall, especially for electric mullions, and the exposed sill block becomes a trip hazard when the mullion is removed, leading to potential damage and reattachment issues during large object movement.
Innovation Solution
An adjustable removable mullion receptacle box with a two-faced safety block that can function as a receiving block or a smooth block, allowing for micro-adjustments to fit the mullion securely without the need for precise angle cuts and providing a flush surface when the mullion is removed to prevent tripping hazards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fixed sill block is used to anchor the mullion bottom, then the mullion is securely anchored, but the exposed block becomes a trip hazard and is easily dislodged when large objects are moved through the opening
Solution Approach 1:
The safety block is made adjustable and reversible, allowing it to be positioned in different orientations. When the mullion is installed, the block is tilted to provide anchoring; when the mullion is removed, the block is flipped to present a smooth surface that eliminates the trip hazard. This dynamic repositioning resolves the contradiction between anchoring strength and safety.
Solution Approach 2:
The safety block is divided into two distinct faces: a receiving block face with a protrusion for anchoring the mullion, and a smooth safety face for when the mullion is removed. This segmentation allows each face to optimize its function - one for strength, the other for safety - without compromise.
2Reliability
If electric strikes are used to secure the mullion, then the mullion can be locked in place, but the mullion becomes difficult to remove and reinstall
Solution Approach 1:
The electric strike system is made dynamically adjustable through the reversible safety block mechanism. The block can be tilted to different angles and positions, allowing the system to adapt between locked and removed states. This dynamic adjustment simplifies the removal and reinstallation process while maintaining locking reliability when needed.
Solution Approach 2:
The position and orientation parameters of the safety block are changed to facilitate easy removal and reinstallation. By adjusting the block's tilt and position, the system transitions between secured and removable states, making operation easier while maintaining reliability when locked.
3Manufacturing precision
If precise angle cuts are required for mullion installation, then accurate fit is achieved, but costly mistakes and delays occur
Solution Approach 1:
The safety block is pre-configured with a receiving protrusion and adjustable positioning features that compensate for variations in mullion angle cuts. This preliminary preparation allows installers to accommodate imprecise cuts without requiring costly rework or causing delays, as the adjustable block can be tilted and positioned to fit various angles.
Solution Approach 2:
The adjustable safety block allows changing of positional and angular parameters to accommodate variations in mullion installation angles. This flexibility eliminates the need for precise pre-cutting while maintaining proper fit, reducing both mistakes and installation time.
Data Source
AI summary
An adjustable mullion receptacle includes a two-sided safety block adapted to sit in the well portion of the mullion receptacle. A receiving block face side of the block is adapted to fit into the hollow bottom of a hollow mullion tube. The opposite side of the block defines a smooth safety face that can be used to set in the receptacle well when the mullion is removed for any purpose. The block then fills the well and provides a smooth surface over the receptacle well.