Flush Mount Component Cover with Recessed Locking Mechanism

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Solution Overview

Problem

Existing wall-mounted systems fail to provide a flush-mounted appearance while allowing for easy removal and maintenance of components, as they either protrude from the wall or require complete disassembly for maintenance.

Innovation Solution

A component cover system that uses a recessed design within the wallboard, secured with a locking mechanism such as magnets or indents, allowing for flush mounting and easy access for maintenance by using a remote or manual means to unlock the cover.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If a component cover is mounted using a bracket along a support strut, then the component is securely mounted, but the component cover extends outward from the wallboard preventing a flush-mounted appearance

Engineering Contradiction:

Improveflush-mounted appearanceVSAvoidinstallation simplicity

Core Design Contradiction:

ShapeVSEase of operation

Solution Approach 1:

The system divides the mounting structure into separate functional elements: a receiver mounted to the wallboard, a component mounted in the receiver, and a component cover that interfaces with both. This segmentation allows each element to be optimized independently - the receiver provides structural support while the cover provides the flush appearance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The receiver acts as an intermediary element between the wallboard and the component cover. It provides a mounting interface that allows the component cover to be secured in a recessed position, achieving flush appearance while maintaining ease of installation through standardized interfaces.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Shape

If a component is hidden behind wallboard with a permanently fixed component cover, then a completely flush-mounted appearance is achieved, but the component cannot be easily removed for maintenance

Engineering Contradiction:

Improveflush-mounted appearanceVSAvoidcomponent accessibility

Core Design Contradiction:

ShapeVSEase of repair

Solution Approach 1:

The component cover transitions from a static, permanently fixed state to a dynamic, removable state. The locking mechanism allows the cover to be secured in place for appearance while enabling easy removal for maintenance, creating a system that adapts between these two states as needed.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The locking mechanism is extracted as a separate functional element that can be engaged or disengaged independently. This allows the component cover to be removed for maintenance while leaving the receiver and mounting structure intact, facilitating easy repair without complete disassembly.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If a locking mechanism is used to secure the component cover, then the cover remains securely mounted, but the locking mechanism becomes visible preventing a clean appearance

Engineering Contradiction:

Improvecover securityVSAvoidappearance cleanliness

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The locking mechanism is nested within the recessed structure, with the component cover fitting over the component and locking interface. This nesting conceals the locking mechanism from external view while maintaining its securing function, achieving both reliability and clean appearance.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The recess structure serves as an intermediary that hides the locking mechanism. By placing the locking interface within the recess rather than on the exterior surface, the system maintains secure mounting while preserving a clean, uninterrupted appearance from the front.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Ease of repair

If the component cover is made removable with a locking mechanism, then easy maintenance is enabled, but the mounting structure becomes more complex

Engineering Contradiction:

Improvecomponent removabilityVSAvoidmounting structure complexity

Core Design Contradiction:

Ease of repairVSDevice complexity

Solution Approach 1:

The receiver serves multiple functions: it provides structural mounting to the wallboard, holds the component, and interfaces with the removable component cover. This multi-functionality reduces the need for separate structures for each function, simplifying the overall system while enabling easy maintenance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 achieves a flush-mounted appearance while enabling easy removal and maintenance of components without the need for complete disassembly, providing a secure and accessible solution for wall-mounted components.

Implementation Method 1

The component cover system uses a recessed design with a locking mechanism, such as magnets or indents, to secure the cover flush with the wallboard

Methodology Applied

Scientific EffectMagnetism: Magnetism

Data Source

PatentUS8245453B2Flush mounting apparatus and methods using component cover

Publication Date: 2012.08.21 DANA INNOVATIONS INC

AI summary

A panel with a bracket is used to install a component to a wallboard. The panel is inserted into an opening to a wallboard, and the junction between the panel and the wallboard is taped and spackled so that the wallboard and panel appear to be a single object. When the component is fully coupled to the bracket, the front of the component is slightly recessed from the front of the panel. A component cover could then be inserted into the newly created recess so that the component appears to be completely flush with the wallboard.