Dry wall extrusion grille frame with seismic tether
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Solution Overview
Problem
Existing grille frame technologies require skilled installers, multiple components, and complex installations, lacking flexibility and the ability to mount flush to walls without structural attachment, which increases installation time and costs.
Innovation Solution
A one-piece dry wall extrusion grille frame with pre-drilled holes, a flexible mounting flange, and a tether for securing the grille panel, allowing for easy installation by non-skilled personnel without additional hardware, enabling flush mounting and customization for various shapes and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional grille frames use corner keys, locks, and multiple planar extensions, then structural strength is improved, but device complexity increases and installation becomes more difficult
Solution Approach 1:
The patent combines multiple separate components (corner keys, locks, planar extensions) into a single integrated extrusion piece. The frame is formed by one continuous extrusion that incorporates all structural elements, eliminating the need for assembly and reducing complexity while maintaining strength through the unified design.
Solution Approach 2:
The single extrusion serves multiple functions simultaneously: it provides structural strength, creates mounting surfaces, forms capture recesses for plaster, and includes pre-drilled holes for installation. This multi-functional design eliminates the need for separate components and simplifies the overall structure.
2Stability of the object's composition
If traditional grille frames require attachment to structural members or studs, then mounting stability is improved, but ease of operation deteriorates due to need for skilled installers
Solution Approach 1:
The frame includes pre-drilled installation holes and pre-formed capture recesses that are created during manufacturing. This preliminary preparation eliminates the need for on-site drilling or complex alignment procedures, allowing installers to simply attach the frame to drywall without requiring specialized skills or tools.
Solution Approach 2:
The frame's design with integrated mounting features and capture recesses allows it to be self-installing on drywall surfaces. The extrusion itself provides all necessary mounting capabilities without requiring attachment to underlying structural members, making the installation process simpler and more accessible.
3Adaptability or versatility
If traditional grille frames use multiple planar extensions, then adaptability to different mounting conditions is improved, but manufacturing cost increases
Solution Approach 1:
The frame design uses a single extrusion that can be cut to various lengths and configured for different applications. This segmentation approach allows the same basic extrusion profile to serve multiple mounting scenarios, reducing the need for different extrusion types and lowering manufacturing costs through standardization.
Solution Approach 2:
The frame's adaptability is achieved through changing dimensional parameters (length, hole positions, recess dimensions) of a single extrusion design rather than creating multiple complex extrusion profiles. This allows customization for different applications while maintaining manufacturing efficiency.
4Ease of manufacture
If traditional grille frames lack integrated tethers, then ease of manufacture is improved, but reliability deteriorates during seismic events
Solution Approach 1:
The tether is integrated directly into the extrusion as a built-in feature rather than being a separate component. This merging of the tether function into the frame structure maintains manufacturing simplicity while ensuring the tether is always present and properly positioned to secure the grille during seismic events.
Data Source
AI summary
A one piece dry wall extrusion grille frame comprising: a frame; pre-drilled installation holes in said frame; a lip for plastering; grille or register; capture recesses for plaster; the grille or register secured to the frame by a tether(s), cable(s) or wire(s) to ensure that the grille or register does not separate from the frame, and no additional hardware for drop in installation.