Reconfigurable Mounting Flange for Flush Electrical Module Installation
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Solution Overview
Problem
Indoor electrical modules, particularly trimless ones, are laborious to install and require accurate positioning to achieve a flush finish, and obstacles like wall frames and plumbing complicate installation, affecting aesthetic appearance and ease of installation.
Innovation Solution
A flange with reconfigurable lines of weakness allows for easy reorientation and folding, combined with a bayonet coupling and clip system, enabling flexible mounting and alignment of power, switch, or data modules, and a socket that adjusts to accommodate various installation conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If trimless electrical modules are used to achieve a flush finish, then aesthetic appearance is improved, but installation complexity increases due to requiring accurate positioning
Solution Approach 1:
The mounting apparatus is divided into a flange portion and a module receiving portion, allowing independent positioning and adjustment. The flange can be separately positioned against the substrate surface while the module is inserted through the opening, enabling easier alignment without requiring precise pre-positioning of the entire assembly.
Solution Approach 2:
The flange acts as an intermediary element between the substrate and the electrical module. It provides a mounting surface that can be positioned against the substrate while the module is inserted through the opening in the flange, facilitating easier installation and adjustment of the module relative to the substrate surface.
2Adaptability or versatility
If obstacles like wall frames and plumbing are present behind the interior surface, then location options are restricted, but installation difficulty increases
Solution Approach 1:
The flange is designed with reconfigurability through lines of weakness that allow it to be folded or bent. This dynamic capability enables the flange to adapt to obstacles behind the substrate surface by changing its configuration, providing installation flexibility in locations with wall frames, plumbing, or other obstructions.
Solution Approach 2:
The flange can change its physical configuration by folding along lines of weakness, altering its shape and position to accommodate obstacles. This parameter change allows the same flange design to be installed in various locations with different obstacle configurations, increasing adaptability without requiring multiple specialized designs.
3Adaptability or versatility
If the flange is made reconfigurable via lines of weakness to facilitate folding and removal, then installation flexibility is improved, but structural strength may be compromised
Solution Approach 1:
The flange is segmented with lines of weakness that create distinct foldable sections. These lines allow the flange to be divided into sections that can be independently positioned, enabling reconfiguration to accommodate obstacles while maintaining sufficient structural integrity in each segment for its specific function.
Solution Approach 2:
The lines of weakness are strategically positioned in specific locations on the flange where reduced strength is acceptable for folding purposes, while other portions of the flange maintain full structural strength for mounting and supporting the electrical module. This local differentiation of quality allows flexibility where needed and strength where required.
Data Source
AI summary
A flange for abutment against and anchorage to a planar supporting surface. A front face of the flange defines a first major surface, and has an outer periphery and an inner periphery. A rear face of the flange defines a second major surface, and has an outer periphery and an inner periphery. An outer rim of the flange extends between the outer periphery of the front face and the outer periphery of the rear face. An inner rim extends between the inner periphery of the front face and the inner periphery of the rear face, and defines an opening extending through the flange. A mounting socket for a power, switch or data module is connected to the flange in alignment with and extending rearwardly from the opening. The mounting socket receives, via the opening, and mounts relative to the flange, the power, switch or data module. The flange is reconfigurable.