Clamping Springs for Electrical Installation Device
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Solution Overview
Problem
Existing electrical installation devices face challenges in simpler and more reliable assembly, particularly in accommodating height tolerances and wallpaper compensation during flush-mounted installations.
Innovation Solution
The integration of clamping springs, designed as one-piece components with the support frame, which provide three clamping points for secure attachment to both the base part and frame, allowing axial and lateral fixation while maintaining axial displacement, thus enabling flexible installation and compensation for height variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If clamping springs are designed as separate components requiring riveting or attachment, then secure connection is achieved, but assembly complexity and time increase
Solution Approach 1:
The clamping springs are integrated directly into the support frame as a single molded component, eliminating separate attachment steps. The support frame and clamping springs form one piece produced via injection molding, where the springs are formed directly in the mold cavity, removing riveting or separate fastening operations entirely.
Solution Approach 2:
The clamping springs are formed self-contained within the support frame structure during molding, with no additional assembly operations needed. The design allows the springs to be created as integral features of the support frame, making the assembly process self-sufficient without external fastening operations.
2Stability of the object's composition
If clamping springs are rigidly fixed at multiple points, then structural stability is improved, but adaptability to height variations is reduced
Solution Approach 1:
The clamping springs are designed with elastic properties that allow dynamic adjustment. The springs can deflect and adapt to varying heights while maintaining clamping force, enabling the assembly to accommodate height tolerances and wallpaper thickness variations without compromising structural stability.
Solution Approach 2:
The spring material and geometry are selected to provide appropriate elasticity and deflection characteristics. The springs can change their physical state through elastic deformation, allowing them to adapt to different height conditions while maintaining secure connection, thus resolving the contradiction between stability and adaptability.
3Strength
If multiple attachment operations are required for secure connection, then connection strength is improved, but manufacturing complexity increases
Solution Approach 1:
The support frame and clamping springs are combined into a single injection-molded component. The molding process creates both the frame structure and the clamping springs in one operation, eliminating multiple attachment steps while maintaining connection strength through the integrated design.
Solution Approach 2:
The mechanical assembly process involving riveting or separate fastening operations is replaced by a single injection molding process. The molding operation directly forms the clamping springs as integral features of the support frame, substituting complex mechanical assembly with a simpler forming process.
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
This design simplifies assembly, ensures secure and quick attachment, and allows for dynamic adjustment of the installation's position to accommodate height tolerances, such as those caused by wallpaper thickness, enhancing the reliability and stability of the electrical installation.
Implementation Method 1
the clamping springs can each be clamped at three clamping points between the base part on the one hand and the frame on the other... the frame is fixed in the axial and lateral direction on the support frame, but remains axially displaceable
Data Source
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AI summary
The device has a circuit board (3), which is fixed on a supporting frame (8). The supporting frame has clamping springs (15a, 15b) for connection of the supporting frame with a retaining part such as a socket part (5) and a blind frame (12). The clamping springs are designed as a single piece with the supporting frame. The clamping spring has two spring legs (16, 17) that stand together in an obtuse angled manner. The supporting frame is manufactured as a plastic-molding part or an injection molding part.