One-Piece Slot Diffuser Frame for Hardware-Free Drywall Mounting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing dry wall slot diffusion frames require multiple planar extensions and complex materials, making them costly and unable to create curved frames, and necessitate additional hardware for installation, which complicates the process and increases labor costs.
Innovation Solution
A one-piece dry wall extrusion frame with self-contained adjustable volume and directional control, featuring a flexible mounting flange, pre-drilled holes, and capture recesses for plaster, allowing for drop-in installation without structural support, enabling easy positioning and secure mounting to walls and ceilings without additional hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple planar extensions and complex materials are used in prior art frames, then structural strength is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent combines multiple frame components into a single extruded piece that integrates the mounting flange, capture recesses, and structural elements into one unified component. This merging eliminates the need for separate planar extensions and complex material assemblies, reducing device complexity while maintaining structural strength through the integrated design.
Solution Approach 2:
The patent changes the structural parameters by using a single extruded profile with optimized geometry that provides both strength and mounting functionality. The extrusion process allows for complex cross-sectional shapes that achieve structural requirements without requiring multiple assembled parts, thereby reducing manufacturing complexity.
2Reliability
If additional hardware and structural supports are required for installation, then mounting reliability is improved, but installation time and labor cost increase
Solution Approach 1:
The frame's mounting flange is designed to be self-contained with integrated capture recesses that directly engage with wallboard compound or adhesive. This self-service design eliminates the need for separate structural supports, beams, or studs, allowing installers to directly mount the frame to drywall or plaster surfaces, thereby reducing installation time while maintaining reliability.
Solution Approach 2:
The frame includes pre-drilled or pre-punched installation holes that are prepared in advance during manufacturing. This preliminary action allows for quick and accurate positioning and securing of the frame without requiring field drilling or complex alignment procedures, significantly reducing installation time while ensuring proper mounting reliability.
3Ease of manufacture
If a one-piece extrusion design is used, then ease of manufacture and installation are improved, but adaptability to curved surfaces is limited
Solution Approach 1:
The patent incorporates curvature capability into the one-piece extrusion design by allowing the extruded profile to be formed in curved or radiused configurations. This enables the frame to adapt to curved surfaces and architectural features while maintaining the manufacturing simplicity and structural integrity of a single extruded piece, thus improving adaptability without sacrificing ease of manufacture.
Data Source
AI summary
A one piece dry wall extrusion frame comprising: a frame, pre-drilled installation holes in said frame; a lip for plastering; volume control or damper control, linear bars or perforated metal; capture recesses for plaster; and not additional hardware for drop in installation.