Flush Mount Insert Support Ring Attachment Mechanism
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Solution Overview
Problem
Existing flush-mounted inserts for electrical/electronic installation devices in domestic technology face challenges in achieving a secure and optimized attachment of the support ring to the device base, particularly in terms of stability and precise positioning.
Innovation Solution
The support ring is attached to the device base through lugs with webs that create a form-fit connection via side cutting edges, which engage with the mechanical interface's side ribs, and guide cylinders ensure precise alignment, while the mechanical interface's reinforcement provides additional stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rivets or bent metal tongues are used to attach the support ring to the device base, then the support ring can be attached to the device base, but the connection lacks sufficient stability and security
Solution Approach 1:
The attachment mechanism is segmented into multiple functional elements: lugs with webs provide form-fit connection, side cutting edges create frictional connection, and guide cylinders enable precise positioning. This segmentation allows each element to contribute specifically to connection stability without requiring a single complex fastening mechanism.
Solution Approach 2:
The tabs are designed to be self-securing through their own deformation. When bent over, the tabs automatically create form-fit connections and frictional connections through their side cutting edges engaging with the mechanical interface, eliminating the need for separate locking mechanisms or tools.
2Manufacturing precision
If the support ring is attached using traditional methods, then attachment is achieved, but precise positioning and alignment are difficult to accomplish
Solution Approach 1:
Guide cylinders are pre-positioned on the device base before the support ring is installed. These guide cylinders protrude through the device base and align with corresponding bores in the support ring, automatically guiding the support ring into precise alignment during installation and preventing rotation.
Solution Approach 2:
The mechanical alignment system replaces traditional manual positioning methods. The guide cylinders and bores create a precise mechanical guidance system that automatically ensures correct positioning and orientation of the support ring relative to the device base during installation.
3Stability of the object's composition
If tabs are bent over to attach the support ring, then attachment is achieved, but movement perpendicular to the support ring can occur
Solution Approach 1:
The web of each tab is locally reinforced with side cutting edges at its end. This local quality enhancement allows the side cutting edges to engage with the mechanical interface and create frictional connections that specifically resist perpendicular movements, while the rest of the tab maintains its form-fit connection function.
Solution Approach 2:
The attachment mechanism combines two types of connections: form-fit connection through the tab deformation and frictional connection through side cutting edges engaging with the mechanical interface. This composite connection approach provides both positional accuracy and resistance to perpendicular forces.
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 solution enhances the stability and secure attachment of the support ring to the device base, allowing for precise positioning and preventing movement perpendicular to the support ring, thus ensuring a robust and reliable connection.
Implementation Method 1
After the forming process, an additional frictional connection is created by the side cutting edges of the webs cutting into the mechanical interfaces in sections.
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The insert (1) has an apparatus base (3) comprising multiple mechanical interfaces (4) at an outer surface. The mechanical interfaces are limited by one of two side ribs of a groove. A support ring (13) comprises multiple tabs (14). The tabs comprise respective bars (15), which are bent in the groove for engaging the support ring at the apparatus base. The bars comprise final-side cuttings (16, 17) i.e. indentations, which are engaged with the side ribs in a bent state of the bars. A front surface of the apparatus base comprises two or multiple guide cylinders.