Reconfigurable Mounting Flange for Flush Electrical Modules
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Solution Overview
Problem
Indoor electrical modules, especially trimless ones, are laborious to install and can be compromised by post-installation work, and their installation is often restricted by obstacles like wall frames and plumbing.
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 flush installation on various surfaces, including those with obstacles.
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 and post-installation work
Solution Approach 1:
The mounting apparatus is divided into a flange portion and a module receiving portion, allowing independent positioning and installation. The flange can be separately mounted to achieve accurate positioning while the module is inserted through the opening, simplifying the overall installation process while maintaining flush finish.
Solution Approach 2:
The flange is pre-mounted to the substrate surface before inserting the electrical module. This preliminary positioning ensures accurate alignment and flush finish is achieved in advance, eliminating the need for complex post-installation work to maintain the flush appearance.
2Adaptability or versatility
If obstacles such as wall frames and plumbing are present behind the interior surface, then location options for electrical modules are restricted, but installation difficulty increases
Solution Approach 1:
The flange is designed with reconfigurability through lines of weakness that allow folding and removal of portions. This dynamic structure enables the flange to adapt to various obstacle configurations behind the substrate, allowing installation in locations that would otherwise be restricted by wall frames or plumbing.
Solution Approach 2:
The flange geometry can be changed by removing portions through the lines of weakness or folding sections at fold lines. This parameter change in the flange structure allows adaptation to different obstacle positions and configurations, expanding location options while maintaining installation feasibility.
3Ease of operation
If the flange is made reconfigurable via lines of weakness to improve adaptability, then ease of installation is improved, but structural strength may be compromised
Solution Approach 1:
The flange is segmented into portions separated by lines of weakness, allowing selective removal or folding of specific sections. This segmentation maintains overall structural integrity while providing reconfigurability for easier installation and adaptation to obstacles.
Solution Approach 2:
The portions of the flange are removed or folded in advance through the lines of weakness before final module installation. This preliminary reconfiguration ensures the flange is optimally shaped for installation while maintaining sufficient strength for the mounting function.
Data Source
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AI summary
Apparatus 300, 300' comprises a flange 302 configured for abutment against and anchorage to the planar supporting surface 402. An operatively front face 302a of the flange 302 defines a first major surface of the flange, and has an outer periphery and an inner periphery. An operatively rear face 302b of the flange 302 defines a second major surface of the flange, and has an outer periphery and an inner periphery. An outer rim 302c of the flange extends between the outer periphery of the operatively front face 302a and the outer periphery of the operatively rear face 302b. An inner rim of the flange 302 extends between the inner periphery of the operatively front face 302a and the inner periphery of the operatively rear face 302b, and defines an opening 304 extending through the flange. A mounting socket 306 for a power, switch or data module 200 is connected to the flange 302 in alignment with and extending rearwardly from the opening 304. The mounting socket 306 receives, via the opening 304, and mounts relative to the flange 302, the power, switch or data module 200. The flange 302 is reconfigurable via at least one line of weakness 308 in the flange.