Glass Faceplate with Elastic Tethers for Wall Dimmers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The use of glass faceplates in wall-mounted electrical control devices is hindered by their fragility and the difficulty of securely attaching them to the wall box without risking breakage and sharp shards, necessitating thicker glass that protrudes from the wall.
Innovation Solution
A thin, tempered glass faceplate is bonded to a plastic carrier and secured to a faceplate adapter with elastic tethers, allowing for secure attachment and preventing accidental drops, while maintaining aesthetic appeal and flush mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If glass is used for the faceplate, then aesthetic appeal is improved, but fragility and safety hazards worsen
Solution Approach 1:
A plastic carrier is introduced as an intermediary between the glass faceplate and the wall box mounting structure. The glass is bonded to this carrier, which absorbs impact and prevents direct contact between the glass and hard surfaces, thereby reducing the risk of breakage into sharp shards while maintaining the aesthetic appeal of the glass surface.
Solution Approach 2:
The plastic carrier serves as a cushioning element that is positioned beforehand between the glass faceplate and potential impact surfaces. This pre-positioned cushioning layer protects the glass from direct impact, reducing the harmful effects of fragility before breakage can occur.
2Object-affected harmful factors
If glass thickness is increased to prevent breakage, then safety is improved, but flush mounting capability worsens
Solution Approach 1:
The plastic carrier acts as a mediator that allows thin glass to achieve the required safety level. The carrier provides structural support and impact absorption, enabling the use of thin glass (less than 3mm) that can be flush with the wall while still providing adequate breakage resistance through the combined structure of carrier plus glass.
Solution Approach 2:
The solution uses a composite structure combining plastic carrier material with glass faceplate. This composite construction provides the benefits of both materials: the plastic carrier offers impact absorption and structural support, while the thin glass provides aesthetic appeal and can be kept flush with the wall surface.
3Reliability
If glass is permanently secured to prevent accidental drops, then reliability is improved, but ease of removal for maintenance worsens
Solution Approach 1:
The mounting system is segmented into multiple components: the glass faceplate bonded to the plastic carrier, and the carrier tethered to the wall box via elastic bands. This segmentation allows the glass to be securely held (improving reliability) while the elastic tether mechanism enables easy removal and reattachment (improving ease of repair) without requiring permanent fixation.
Solution Approach 2:
The elastic bands provide a dynamic mounting solution that adapts between secured and removable states. The elastic property allows the carrier to be held securely in the mounted position (improving reliability) while enabling easy removal and reattachment for maintenance (improving ease of repair) without permanent damage to components.
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 ensures the glass faceplate is securely attached, prevents breakage into sharp shards, and remains flush with the wall, providing a safe and visually appealing solution for wall-mounted electrical controls.
Implementation Method 1
The carrier is further pivotably tethered to the faceplate adapter, as by one or more thin bands, preferably elastic, so that when the faceplate is removed from the wall box, the tether will prevent the accidental dropping of the faceplate
Implementation Method 2
Since the glass is tempered if it is dropped for any reason onto a hard surface, if fractured, it will fracture in small pieces without sharp edges
Data Source
AI summary
A glass faceplate is cemented to a plastic carrier which can be removably connected to the adapter plate of a wall box dimmer. The glass plate is a flat tempered glass which may be suitably colored or clear and has a thickness less than three millimeters. Two elastic tethers are connected at one end to the carrier plate and at the other end to the adapter plate to serve as a pivotal connection at the bottoms of the two plates and prevent the accidental fall and breakage of the glass faceplate.