Electrical Mullion Receptacle Box Assembly
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Solution Overview
Problem
Conventional electric mullions pose challenges in removability and installation due to trip hazards caused by sill blocks and complex cable connections, violating accessibility standards like the Americans with Disabilities Act, and requiring notched thresholds that further complicate installation and safety.
Innovation Solution
A mullion receptacle box assembly with a toe plate, channel, and block components that allow the bottom of the mullion to be securely nested in a threshold receptacle without protrusions, enabling easy removal and reinstallation while maintaining a uniform threshold, using a removable toe plate and secure screw mechanisms to prevent disconnection and ensure a flat surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sill blocks are used to anchor the mullion at the threshold, then the mullion can be securely anchored, but protrusions are created that become trip hazards and violate accessibility standards
Solution Approach 1:
The invention extracts the anchoring function from the traditional sill block that protrudes into the opening. Instead, the mullion is anchored at the threshold using a receptacle system where the mullion bottom is received and secured within the threshold plane, eliminating protruding elements while maintaining secure anchoring.
Solution Approach 2:
The invention moves the anchoring mechanism from a vertical protrusion dimension to a horizontal recess dimension. The mullion is anchored within the threshold plane rather than having components extend upward into the opening, effectively using the threshold thickness dimension to accommodate the anchoring mechanism without creating trip hazards.
2Reliability
If electric cable connections are made at the top of the mullion, then electrical power can be supplied to the electric strike, but the mullion becomes difficult to remove and reinstall
Solution Approach 1:
The invention segments the electrical connection system into separate components: a fixed electrical receptacle in the threshold and a detachable connector on the mullion. This allows the mullion to be removed and reinstalled by simply connecting and disconnecting the electrical plug, maintaining reliable electrical power supply while greatly improving ease of operation.
3Ease of manufacture
If a notched threshold is created to accommodate the sill block, then the sill block can be mounted to the floor, but the notched threshold becomes exposed and may become a trip hazard when the mullion is removed
Solution Approach 1:
The invention eliminates the need for notched thresholds by extracting the anchoring function to a different location and method. The mullion is anchored within the threshold plane using a receptacle system, so no notches or slots are required in the threshold surface, maintaining a smooth, continuous threshold that eliminates trip hazards.
4Strength
If the threshold is made thicker to accommodate the sill block mounting, then the sill block can be securely mounted, but the threshold exceeds the 1/2 inch limit set by the Americans with Disabilities Act
Solution Approach 1:
The invention uses the threshold thickness dimension to accommodate the anchoring mechanism internally, rather than requiring the threshold to be thicker overall. The receptacle system is embedded within the standard threshold thickness, allowing secure anchoring while maintaining compliance with the 1/2 inch maximum thickness requirement for accessible routes.
Data Source
AI summary
A door mullion receptacle box assembly includes a toe plate, a channel box and block components. When a mullion is removed from a building/room opening, the toe plate may be fixed in the mullion receptacle box thus creating a uniform threshold across the width of the door openings. Using the assembly described herein, however, there are no large diameter holes in the top of the toe plate and no projections into the opening that could be a trip hazard. The present assembly replaces traditional fixed sill blocks mounted to the floor, or to the top of a threshold to anchor the bottom of conventional mullions. A typical mullion is locked in place with a lock at the top of the mullion. When installed, this mullion is placed over the sill block at the sill and tilted into place and locked into a header block at the top of the mullion. However because the components of the conventional sill blocks project up into the mullion from the thresholds, they become a trip hazard and a liability when the mullion is temporarily removed.