Adjustable Electrical Wall Mounting for Flush Surface Alignment
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Solution Overview
Problem
Existing electrical assembly mounting systems fail to provide a seamless, flush integration with various building surfaces, leading to aesthetic discontinuities and requiring tedious and inconvenient installation processes.
Innovation Solution
A system comprising a wall structure with brackets, base and mounting plates, and magnetic cover plates, utilizing adjustable threaded fasteners to ensure the electrical component's outer surface is flush with the wallboard, allowing for precise alignment and magnetic securing for a seamless finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional electrical assemblies are mounted to surfaces, then the electrical components can be installed and functional, but the components protrude from the surface creating aesthetic discontinuities
Solution Approach 1:
The mounting system is divided into separate functional components: a mounting plate with adjustment mechanism, an electrical component holder, and a surface plate. This segmentation allows each component to be optimized independently - the mounting plate provides adjustment capability, the holder secures the electrical component, and the surface plate achieves the flush appearance, resolving the contradiction between precision and ease of installation.
Solution Approach 2:
The mounting plate incorporates dynamic adjustment features including threaded rods and slots that allow the electrical component to be positioned at varying distances from the surface during installation. This dynamic capability enables installers to achieve precise flush mounting on different surface types while maintaining ease of operation through simple rotational and sliding adjustments.
2Manufacturing precision
If adjustable mounting mechanisms are used to achieve flush mounting, then aesthetic appearance is improved, but the device complexity increases
Solution Approach 1:
The mounting system uses a nested structure where the electrical component is held within a component holder, which is attached to the mounting plate, which in turn connects to the surface plate. This nesting allows the complex adjustment mechanism to be contained within a compact form factor, achieving precise surface alignment without excessive external complexity.
Solution Approach 2:
The mounting plate serves as an intermediary element between the electrical component and the surface. It provides the adjustment mechanism (threaded rods, slots) needed for precise positioning while keeping the electrical component and surface plate relatively simple, thus achieving high alignment precision without overall system complexity.
3Manufacturing precision
If multiple fasteners and adjustment mechanisms are used, then mounting precision is improved, but the installation process becomes more tedious
Solution Approach 1:
The mounting plate is pre-configured with threaded rods, slots, and attachment points during manufacturing. This preliminary preparation allows installers to simply adjust and secure the component in the desired position without having to assemble complex mechanisms during installation, reducing installation time while maintaining positioning precision.
Solution Approach 2:
The threaded rods and slots are designed to be self-adjusting, allowing installers to easily position the electrical component at the correct distance from the surface by simple rotation and sliding movements. The system serves itself by providing built-in adjustment capabilities that require minimal skill or time to operate, achieving precise positioning without tedious assembly steps.
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 system enables a seamless transition between electrical components and building surfaces, enhancing aesthetics while simplifying the installation process by combining inspection and installation stages, reducing labor and costs.
Implementation Method 1
at least one mounting plate magnet magnetically couples with the at least one cover plate magnet
Data Source
AI summary
A system for adjustably mounting a component of an electrical assembly to a wall structure; the wall structure including at least a wallboard. The system is configured so that an outward facing surface of the component may be adjustably positioned relative to the outward facing surface of the wallboard. The system comprises of a bracket disposed between adjacent studs of a wall structure, a base plate, a mounting plate, a cover plate, protective plate, an electrical component fastener, and an electrical component opening. A method for adjustably mounting a component of an electrical assembly to a wall structure comprising a mounting plate, a base plate, a bracket, a stud of the wall structure, a planar surface of the wall structure with adhesive, threaded fasteners, a component of an electrical assembly, a cover plate, and a protective plate.