Leveling Bezel Assembly for Flush Poke-Through Outlet Mounting
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Solution Overview
Problem
Conventional power and data systems face issues with bezel alignment when the opening in the mounting surface is not orthogonal to the plane, leading to an undesirable appearance and potential trip hazards or debris accumulation, and re-drilling can result in an oversized bore and insecure mounting.
Innovation Solution
A poke-through electrical power and data unit with a repositionable upper bezel relative to a lower housing, enabled by non-rigid coupling fasteners that allow axial and tiltable adjustments, accommodating variations in opening orientations and ensuring the bezel can be set flush during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the opening in the mounting surface is not orthogonal to the plane, then the installation can proceed without re-drilling, but the bezel cannot mount straight and flush with the surface, creating an undesirable appearance and potential trip hazard
Solution Approach 1:
The patent applies the dynamics principle by making the lower insert tiltable relative to the upper bezel through non-rigid coupling fasteners. This allows the insert to dynamically adjust its orientation to accommodate non-orthogonal bores, enabling the bezel to mount flush with the surface even when the opening is not perfectly perpendicular, thus resolving the contradiction between ease of installation and bezel alignment precision
Solution Approach 2:
The patent changes the orientation parameter of the lower insert by allowing it to tilt up to approximately five degrees from alignment with the longitudinal axis of the upper bezel. This parameter change enables the system to accommodate variations in bore orientation without requiring precise orthogonal drilling, thereby maintaining both installation ease and bezel alignment
2Manufacturing precision
If re-drilling is performed to correct misalignment, then the bezel can be properly oriented, but the bore becomes oversized and the poke-through unit cannot be securely mounted
Solution Approach 1:
The tiltable lower insert provides a dynamic adjustment mechanism that accommodates non-orthogonal bores without requiring re-drilling. This maintains the original bore size and allows secure mounting through the non-rigid coupling fasteners, eliminating the need to sacrifice mounting security for alignment correction
Solution Approach 2:
The non-rigid coupling fasteners act as an intermediary element between the upper bezel and lower insert, allowing relative movement and orientation adjustment. This intermediary mechanism enables proper bezel alignment while maintaining secure mounting in the original bore without re-drilling
3Stability of the object's composition
If the bezel is rigidly coupled to the lower housing, then the structure is stable, but the bezel cannot be repositioned to accommodate opening variations
Solution Approach 1:
The patent transforms the rigid coupling into a dynamic, non-rigid coupling that allows the lower insert to tilt and adjust its position. This dynamic coupling maintains structural stability while providing the adaptability needed to accommodate variations in opening orientation and position
Solution Approach 2:
The patent segments the coupling system into an upper bezel and a lower insert that can move independently relative to each other. This segmentation allows the lower insert to adjust to opening variations while the upper bezel maintains its stable, flush mounting position
Data Source
AI summary
An electrical outlet assembly is mountable in a floor or work surface, and includes an upper bezel and a lower insert that are joined in a non-rigid manner that permits some adjustment to the spacing and/or tilt of the upper bezel relative to the lower insert. The upper bezel and lower insert are joined together by a plurality of fasteners extending between a plurality of fastener receivers coupled to the upper bezel, and to the lower insert. At least one end of each coupling fastener is loosely captured in such a way that when the coupling fasteners are fully secured, they are permitted to move axially relative to the fastener receiver or the lower insert. This allows the lower insert to be repositionable in its axial direction relative to the upper bezel, and also permits the lower insert to be tilted out of alignment with the upper bezel.