Modular Keypad Faceplate Assembly for Flexible Button Placement
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Solution Overview
Problem
Home automation systems face challenges in designing compact, modular, and aesthetically pleasing control devices that can mount outside electrical wall boxes, providing flexibility in button placement and easy connection to various electrical loads while maintaining structural integrity and aesthetic appeal.
Innovation Solution
The control device features a compact faceplate subassembly with posts that secure a circuit board and back cover to the faceplate, allowing buttons to be mounted outside the wall box perimeter, and includes modular electrical connections for easy load control, along with illumination for user feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If buttons are mounted outside the wall box perimeter, then flexibility in button placement and aesthetic appeal are improved, but structural integrity and mounting stability may worsen
Solution Approach 1:
The control device is divided into a faceplate subassembly (containing buttons) and a main control module subassembly (mounting to wall box). This segmentation allows the button-containing faceplate to extend beyond the wall box perimeter for aesthetic and flexibility purposes, while the main control module remains securely mounted within the wall box, maintaining structural integrity.
2Volume of moving object
If a compact faceplate subassembly is used, then aesthetic appeal and space efficiency are improved, but ease of assembly and manufacturing complexity may worsen
Solution Approach 1:
The device is segmented into a faceplate subassembly and a main control module subassembly that can be manufactured separately and then assembled together. This allows the faceplate to be compact and aesthetically pleasing while the main control module contains the bulk of the electronic components, making both parts easier to manufacture independently.
Solution Approach 2:
A carrier is introduced as an intermediary component between the faceplate and the main control module. The carrier facilitates the connection between these two subassemblies, simplifying the assembly process while maintaining the compact design of the overall device.
3Ease of operation
If modular electrical connections are implemented, then ease of connection to electrical loads is improved, but device complexity may worsen
Solution Approach 1:
The control device is designed with universal electrical connection capabilities that can interface with various types of electrical loads through standardized connection interfaces. This modularity allows the same device to control different loads (lights, appliances, etc.) without requiring complex custom wiring for each application.
Data Source
AI summary
A control device for controlling power delivered to an electrical load includes a faceplate subassembly and a main control module. The faceplate subassembly includes a faceplate, a button, a circuit board, and a back cover. The faceplate includes a front surface and an opposed rear surface, and an opening extending therebetween with the button disposed in the opening in the faceplate. The back cover is positioned adjacent to the circuit board and defines a plurality of holes. A shaft of a post extending from the faceplate is disposed in one of the holes in the back cover and an end of the post is enlarged such that the back cover is captured between the end of the post and the rear surface of the faceplate. The main control module is configured to cause power delivered to the electrical load to be adjusted in response to depression of the button.