Modular Wall Box System Segmentation

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Solution Overview

Problem

Conventional wall box devices integrate load actuation and user interface functionality, leading to aesthetic issues when ganging devices from different vendors or series, requiring costly and wasteful replacement of entire devices for interface upgrades, and necessitating redundant certification processes for manufacturers.

Innovation Solution

A modular wall box system decouples load actuating devices from user interfaces, allowing them to be treated as separate entities for design, installation, and maintenance, with standardized power and communication components enabling various user interfaces to operate with multiple load actuating devices, and allowing certification of load actuating devices without final user interfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If load actuating devices from different vendors or series are ganged together, then more device options are available, but aesthetic consistency deteriorates due to different materials, dimensions and color variations

Engineering Contradiction:

Improvedevice optionsVSAvoidaesthetic consistency

Core Design Contradiction:

Adaptability or versatilityVSShape

Solution Approach 1:

The device is divided into two independent modules: a load actuating module and a user interface module. The user interface module can be detached and replaced without affecting the load actuating module, allowing different interface styles to be matched for aesthetic consistency while maintaining device functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A universal mounting interface is designed that can accommodate different user interface modules on a single load actuating device. This allows one load actuating module to work with multiple different user interface styles, providing both versatility and aesthetic consistency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If the entire device is replaced to upgrade the user interface, then the latest interface technology is achieved, but cost and waste increase due to discarding functional load actuators

Engineering Contradiction:

Improveinterface technologyVSAvoidfunctional component waste

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The device is segmented into replaceable user interface modules and permanent load actuating modules. Only the interface module needs to be replaced for technology upgrades, while the functional load actuator is preserved and reused, eliminating waste.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The user interface module is extracted as a separate, independently replaceable component from the load actuating device. This allows the interface to be upgraded without removing or discarding the functional load actuator, reducing material waste.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If licensed electricians perform interface changes in commercial applications, then safety is ensured, but installation cost increases beyond the component cost

Engineering Contradiction:

Improveinstallation safetyVSAvoidinstallation cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The electrical connections are segmented into permanent hardwired connections for the load actuator and removable connections for the user interface. This allows non-electricians to safely replace interfaces without touching live electrical components, reducing installation costs while maintaining safety.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A terminal block serves as an intermediary component that provides isolated, pre-wired connection points. This allows users to connect interfaces without directly handling electrical wires, enabling safe installation by non-licensed personnel while maintaining electrical safety.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If manufacturers certify each new product series, then compliance with building codes is ensured, but development time and cost increase due to redundant certification processes

Engineering Contradiction:

Improvecode complianceVSAvoiddevelopment efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

A universal load actuating module is designed that can be certified once and then paired with multiple different user interface modules. The certified core component maintains compliance across different product variants, eliminating redundant certification processes while ensuring ongoing code compliance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS7906873B1Modular wall box system

Publication Date: 2011.03.15 INNCOM INTERNATIONAL INC

AI summary

A device is provided and includes an actuator, mounted to a wall box, including a power supply, a semi-conductor switch, an electrical load controller and a terminal coupled to the power supply and the controller, an actuator interface disposed to receive first commands relating to basic electrical load control by the controller and a separate interface, including a header to communicate with the terminal whereby the separate interface receives power and communicates with the controller, the separate interface being supportable at the wall box and, when the header and terminal communicate, configured to identify a type of the semi-conductor switch of the actuator and to receive second commands of a type unique to the identified actuator type and relating to the basic and enhanced electrical load control by the controller.