Flat Switch Sensor Nesting for NEC Compliance
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Solution Overview
Problem
In the U.S., the installation of switch boxes according to NEC standards requires the switch box's end part not to protrude 6.4 mm or deeper from the wall's front surface, leading to a poor appearance when the sensor unit of a flat switch protrudes due to its thickness, even if it's relatively thin.
Innovation Solution
A flat switch design with a sensor unit that has a thicker section than the protruding edge of the switch box, utilizing an attaching plate with an accommodating part and elastic support to ensure the sensor unit is flush with the switch box's edge, allowing it to be embedded within the box without protruding from the wall.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the sensor unit is provided on the end part on the opening side of the switch box, then the switch box can be installed in compliance with NEC standards, but the sensor unit protrudes from the appearance surface resulting in poor appearance
Solution Approach 1:
The sensor unit is nested within a recessed accommodating part formed in the attaching plate. The accommodating part has a depth that allows the sensor unit to be positioned below the outer peripheral edge part of the attaching plate, which itself is positioned at the peripheral edge part of the switch box. This nesting structure enables the sensor unit to be hidden within the switch box boundaries, maintaining appearance flatness while allowing NEC-compliant installation.
Solution Approach 2:
The solution addresses the protrusion problem by utilizing the depth dimension (Z-axis) rather than reducing the sensor unit thickness. The accommodating part provides a recessed space in the depth direction, allowing the sensor unit to be positioned at a different depth level while maintaining the same outer footprint. This dimensional approach resolves the contradiction between maintaining sensor functionality and achieving appearance flatness.
2Shape
If the sensor unit is made thinner to avoid protrusion, then appearance flatness is improved, but the sensor unit may not have sufficient thickness for proper sensor operation
Solution Approach 1:
The attaching plate is segmented into different functional zones: an outer peripheral edge part that defines the boundary, and an inner accommodating part with recessed bottom surface that houses the sensor unit. This segmentation allows the sensor unit to maintain its required thickness for proper operation while being positioned in a recessed area that prevents protrusion beyond the outer boundary.
Solution Approach 2:
The accommodating part acts as an intermediary structure between the sensor unit and the switch box exterior. It provides a recessed environment that accommodates the sensor unit's thickness requirements while preventing the sensor unit from protruding beyond the acceptable boundary defined by the outer peripheral edge part.
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 prevents the flat switch from protruding, maintaining a clean appearance even when installed in compliance with NEC standards, by ensuring the sensor unit is flush with the switch box's edge, accommodating its thickness within the specified depth.
Implementation Method 1
an elastic part that is provided on the bottom surface and elastically supports the sensor unit
Data Source
AI summary
A flat switch is provided that prevents the flat switch from protruding and thereby causing a poor appearance even in a case where it is required to install a switch box so that an end part on an opening side of the switch box is not positioned on a predetermined distance or deeper side with respect to an appearance surface that is a surface of a wall. A flat switch (1) of the present invention is a flat switch (1) that is installed in a switch box (100) having a bottom part (101) and a vertical wall part (102) which is provided along an outer periphery of the bottom part (101). The switch box (100) is installed so that, with respect to an appearance surface that is a front surface of a wall, a peripheral edge part (102A) is not positioned on a predetermined distance or deeper side in a depth direction of the wall from the appearance surface. The flat switch (1) includes a sensor unit (20) whose thickest part in a direction from the peripheral edge part (102A) of the switch box (100) to the bottom part (101) is thicker than a predetermined distance in a state of being installed in the switch box and whose outer shape is smaller than an inner shape of the peripheral edge part (102A) of the switch box (100).