Snap-on Wall Plate Assembly with Biasing Connectors
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Solution Overview
Problem
Existing wall plate attachment mechanisms for electrical devices are not sufficiently secure, easy to install, or adaptable to uneven surfaces, and often require visible fasteners or complex components.
Innovation Solution
A snap-on wall plate assembly with a base plate and cover plate that uses a biasing connector system with inclined teeth and latch members for secure attachment, allowing independent adjustment of each corner for a snug fit against the wall, and includes a gasket for a weatherproof seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional screw attachment mechanisms are used, then secure attachment is achieved, but visible fasteners and complex installation are required
Solution Approach 1:
The patent replaces the traditional screw-thread mechanical fastening system with a snap-fit mechanism using resilient arms and lugs. The cover plate's resilient arms with lugs engage with corresponding features on the base plate, providing secure attachment without visible fasteners. This substitution maintains attachment reliability while dramatically simplifying installation to a simple snap-in operation.
2Adaptability or versatility
If a fixed rigid wall plate is used, then manufacturing simplicity is achieved, but adaptability to uneven surfaces is lost
Solution Approach 1:
The patent introduces dynamic elements to the wall plate structure, specifically resilient arms that can flex and adjust. These arms are positioned at corners and can independently move to accommodate variations in wall surface flatness. The dynamic capability allows the rigid cover plate to adapt to uneven surfaces while maintaining a simple overall structure without requiring complex adjustment mechanisms.
3Reliability
If multiple separate attachment components are used, then secure attachment is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple attachment functions into integrated features. The resilient arms are formed as integral parts of the cover plate, and the lugs are incorporated directly into the arm structure. This merging eliminates the need for separate fasteners, clips, or attachment components, reducing the total part count while maintaining secure attachment through the combined resilient-lug mechanism.
4Ease of operation
If a simple snap mechanism is used, then ease of installation is achieved, but attachment security and reliability are reduced
Solution Approach 1:
The patent employs cam surfaces with curved geometries on the resilient arms. As the cover plate is snapped into place, these cam surfaces guide the lugs onto the base plate features through a controlled curved path. The curvature provides mechanical advantage, allowing simple snap-in installation while ensuring positive engagement and secure attachment. The cam action transforms the simple snapping motion into a reliable locking engagement.
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 provides a secure, easy-to-install, and adjustable wall plate assembly that fits uniformly against the wall surface, ensuring a neat appearance without visible fasteners and accommodating uneven surfaces, while maintaining a weatherproof seal.
Implementation Method 1
A resilient arm is positioned at each corner of the cover plate and extends into a corresponding recess in the base plate. The resilient arm has a cam surface and an inclined cam surface that engages a cam surface on the latch member. As the cover plate is snapped onto the base plate, the resilient arm flexes to allow engagement of the cam surfaces and then maintains contact force.
Data Source
AI summary
The wall cover plate assembly includes a base and a cover for connecting to an electrical box and an electrical wiring device. The base is connected to the electrical box and/or the electrical wiring device by suitable fasteners. The base includes a first coupling member positioned along opposite side edges and second coupling members positioned at each corner of the base plate. A cover includes a first coupling member for engaging the first coupling member on the base plate and connectors for engaging the second coupling members on the base plate. The connectors of the cover are angled with respect to a plane of the cover to engage a connecting member of the second coupling members. The connectors provide a biasing force to engage the second coupling members of the base which increase when the cover plate is pulled outwardly from the base.