Self-Adjusting Mounting Frame for Flush Wall Faceplate Alignment

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Wall-mounted control devices often suffer from misalignment and warping issues due to improper installation, leading to unsightly gaps between the faceplate and the wall surface.

Innovation Solution

A self-adjusting mounting frame with biasing members, such as resilient spring arms, that attaches to the yoke of the mechanical switch and biases against the wall surface, allowing the frame to self-adjust and minimize gaps during installation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the wallbox is misaligned with respect to the wall surface during installation, then the mounting process becomes simpler and faster, but the faceplate becomes angularly offset and gaps form between the faceplate and wall surface

Engineering Contradiction:

Improvemounting process simplicityVSAvoidfaceplate alignment precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The mounting frame incorporates resilient biasing members that change the physical state from rigid to flexible, allowing the frame to adapt to misaligned wallboxes while maintaining faceplate alignment with the wall surface

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The mounting frame transitions from a static rigid structure to a dynamic system with resilient biasing members that can deflect and adjust, enabling the frame to self-adjust to installation variations and maintain proper faceplate alignment

Inventive Principle:

Principle #15Dynamics

2Strength

If faceplate screws are tightened to secure the faceplate to the yoke, then the faceplate attachment becomes more secure, but the outer surface of the faceplate becomes warped and gaps form

Engineering Contradiction:

Improvefaceplate attachment securityVSAvoidfaceplate surface flatness

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The mounting system is divided into separate functional components: the mounting frame that provides structural support and alignment, and the faceplate that provides the aesthetic finish, connected through resilient biasing members that isolate mechanical stresses

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Resilient biasing members are introduced as intermediary elements between the mounting frame and faceplate, absorbing installation stresses and preventing warping while maintaining secure attachment

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If a rigid mounting frame is used to maintain structural stability, then the mounting structure becomes more stable, but the frame cannot adapt to wallbox misalignment and gaps form

Engineering Contradiction:

Improvemounting structure stabilityVSAvoidadaptation to wallbox misalignment

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The mounting frame incorporates resilient biasing members that enable dynamic adjustment, allowing the otherwise stable rigid structure to adapt to misaligned wallboxes by deflecting and repositioning as needed during installation

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution ensures proper alignment and contact with the wall surface, eliminating gaps and providing a visually appealing installation without requiring re-wiring or replacing existing switches.

Implementation Method 1

The mounting frame may include one or more biasing members that are configured to bias a rear surface of the mounting frame against a surface of structure, such as a wallboard surface that surrounds the wallbox

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

Each biasing member may include an attachment portion and a pair of resilient spring arms that suspend the attachment portion relative to a perimeter wall of the mounting frame

Methodology Applied

Scientific EffectSpring: Spring

Data Source

PatentUS12512278B2Self-adjusting frame for mounting over a wall-mounted electrical device

Publication Date: 2025.12.30 LUTRON TECHNOLOGY COMPANY LLC

AI summary

A mounting frame may be configured as a self-adjusting mounting frame that biases itself against a surface of structure. The mounting frame may be a component, for example, of a remote control device or a faceplate assembly. The mounting frame may be configured to bias a rear surface of the mounting frame against the surface of a structure. The mounting frame may include biasing members. Each biasing member may include an attachment portion and a pair of resilient spring arms that suspend the attachment portion relative to a perimeter wall of the mounting frame such that the attachment portion is spaced further from the rear surface of the mounting frame than locations where the spring arms extend from the mounting frame. The rear surface of the mounting frame may be defined by the perimeter wall.