Flush-Mounted Electrical Assembly With Split Base And Recessed Relay
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Solution Overview
Problem
Existing electrical assemblies for flush-mounted installations in walls are not compact enough to incorporate smart functionalities effectively, as they require deeper built-in depths due to the placement of electronic circuitry and large components like relays.
Innovation Solution
A base with multiple parts and split electronic circuitry, where the second electronic circuitry is positioned on a PCB between the front and rear base parts, allowing for a more compact design and better antenna reception, with the relay located in a recess to minimize depth, and incorporating microcontrollers for smart functionality and power measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electronic circuitry and relay are placed in a conventional single-base design, then the electrical assembly can perform basic functions, but the built-in depth becomes too large to accommodate smart functionalities effectively
Solution Approach 1:
The base is divided into a rear base part and a front base part, with electronic circuitry distributed between them. The rear base part contains power conversion circuitry and the front base part contains control circuitry, allowing smart functionalities to be integrated without increasing overall depth.
Solution Approach 2:
The relay is positioned in a recess on the rear side of the rear base part, utilizing the depth dimension strategically. This recess placement allows the relay to be accommodated without increasing the overall built-in depth of the assembly.
2Reliability
If relay is positioned at the rear of the base, then basic electrical functions are achieved, but the antenna reception is compromised due to distance from the front
Solution Approach 1:
The base is segmented into front and rear parts, allowing the relay to be placed in a recess on the rear part while the front part remains available for antenna placement. This segmentation enables both good antenna reception and proper relay positioning.
Solution Approach 2:
The relay is nested within a recess in the rear base part, creating a compact structure that accommodates the relay without increasing overall depth while maintaining space for antenna elements in the front base part.
3Length of stationary object
If all electronic circuitry is placed on a single PCB, then manufacturing is simplified, but the assembly cannot achieve compact dimensions with split functionality
Solution Approach 1:
Electronic circuitry is divided between the front and rear base parts, with each part containing its own PCB. This segmentation enables compact depth while maintaining manufacturing simplicity through modular assembly of the front and rear base parts.
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
An electrical assembly for flush-mounted installation in a wall, comprising a base and a cover, said base comprising an electrical function and being intended for being at least partially built-in in an opening in the wall, said cover being configured for being attached to said base and for covering said opening; wherein said base comprises a rear base part, and a front base part; the rear side of said rear base part facing away from said cover and the front side of the rear base part being attached to a rear side of said front base part, said front side of said front base part facing towards said cover; wherein said rear base part is provided with first electronic circuitry connected to the electrical function; wherein said front base part is provided with second electronic circuitry which is connected to said first electronic circuitry.