Molded Decorative Keys for Electrical Wiring Devices
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Solution Overview
Problem
The high cost and esthetic issues associated with using glass or crystal decorative panels and keys in electrical wiring systems, due to the expensive processing of glass components and the difficulty in achieving precise right-angle corners, lead to a need for cost-effective and aesthetically pleasing solutions that unify the finishing and colors of various electrical devices.
Innovation Solution
The development of decorative keys and panels made from clear or tinted sheet glass or crystal, or molded using transparent materials, which are designed to match the size and color of standard AC switches and outlets, incorporating features like flat surfaces and indicators for hybrid switches, and the use of plug-in devices with optical transceivers and RFID antennas for unified communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If glass or crystal decorative panels and keys are used, then aesthetic quality is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive glass or crystal decorative panels and keys with inexpensive plastic materials that can be easily molded. The plastic covers and keys provide the necessary aesthetic function at a fraction of the cost of glass or crystal, making them economically viable for widespread use in electrical wiring devices.
Solution Approach 2:
The patent changes the material parameter from glass/crystal to plastic, which fundamentally alters the manufacturing process from cutting and polishing to molding. This parameter change enables mass production at lower costs while maintaining aesthetic qualities through molded designs that can incorporate colors, patterns, and three-dimensional effects.
2Shape
If glass panels are cut with rotating diamond grinder, then decorative appearance is improved, but manufacturing precision deteriorates due to rounded corners
Solution Approach 1:
The patent replaces difficult-to-process glass panels with plastic materials that can be molded into precise shapes including sharp right-angle corners. The molding process naturally produces the desired corner precision without requiring complex grinding operations, eliminating the rounded corner problem inherent in glass processing.
Solution Approach 2:
The patent replaces the mechanical grinding process (rotating diamond grinder) with a molding process. Instead of cutting and shaping glass through mechanical removal of material, the plastic covers and keys are formed directly into the desired shape with precise corners through mold cavities, achieving both aesthetic appearance and manufacturing precision.
3Manufacturing precision
If decorative thin plastic frames are added to provide right-angle corners, then manufacturing precision is improved, but device complexity increases due to bulging surfaces
Solution Approach 1:
The patent merges the frame and the cover into a single integrated plastic molding. Instead of adding separate decorative frames to glass panels, the plastic cover is molded as one piece with integrated framing elements that provide the necessary corner precision and aesthetic appearance without creating bulging surfaces. The entire assembly maintains a flat profile suitable for architectural applications.
Data Source
AI summary
A flat decorative frame made of rectangular crystal or glass or molded transparent or tinted plastic materials for providing assembly of right angle architectural decorative cover with right angle rectangular or square opening access for power outlet and push keys operating electrical hybrid or manual switches by tactile action of a tactile spring including a matching decorative touch icons panel with the panels and the keys including indicators indicating the load status and the keying position for the manual and hybrid switches.