Split Block Multiaxis Living Hinge for Watertight Fixture Mounting
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Solution Overview
Problem
Conventional split block designs for construction siding suffer from increased manufacturing complexity and labor requirements for multipiece backplates, and single-piece designs face water penetration issues.
Innovation Solution
A single-piece split block assembly with a multiaxis living hinge system, integrally formed from a resilient thermoplastic polymer, allowing for easy installation and improved water protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multipiece backplate designs are used, then ease of installation is improved, but device complexity and manufacturing time increase
Solution Approach 1:
The backplate is divided into two segments that can pivot relative to each other about a penetration, allowing the backplate to open for installation around fixtures and close for a finished appearance. This segmentation enables ease of installation while maintaining a single-piece integral construction that reduces overall device complexity.
Solution Approach 2:
The backplate incorporates a living hinge that allows dynamic movement between open and closed positions. This dynamic feature enables the backplate to adapt during installation (open position) and provide a finished appearance (closed position), resolving the contradiction between ease of installation and device complexity.
2Device complexity
If single-piece backplate designs are used, then device complexity is reduced, but water penetration issues occur
Solution Approach 1:
The backplate is segmented into two pivotable sections that can close around the penetration, creating a more reliable water-resistant configuration compared to a traditional single rigid piece, while still maintaining integral construction without separate fastening components.
Solution Approach 2:
The living hinge provides flexible movement capability within the integral backplate structure, allowing the backplate to conform and seal around the penetration effectively, thereby improving water protection while maintaining device simplicity.
3Adaptability or versatility
If multipiece backplate designs are used, then adaptability to fixtures is improved, but manufacturing time and labor increase
Solution Approach 1:
The backplate is divided into two segments that can pivot about the penetration, allowing adaptation to various fixture sizes and shapes while still being manufactured as a single integral piece, thereby improving adaptability without increasing manufacturing complexity.
Solution Approach 2:
The living hinge mechanism provides universal adaptability to different fixture configurations while maintaining a standardized single-piece manufacturing process, enabling the backplate to serve multiple installation scenarios without requiring different manufactured components.
4Ease of manufacture
If single-piece backplate designs are used, then manufacturing cost is reduced, but water penetration issues occur
Solution Approach 1:
The backplate incorporates two pivotable segments that can close around the penetration to improve water protection, while the entire assembly remains a single integral piece manufactured in one operation, maintaining manufacturing cost-effectiveness.
Solution Approach 2:
The living hinge provides flexible movement capability within the integral backplate structure, allowing effective sealing around the penetration at minimal additional manufacturing cost, as the flexibility is achieved through the hinge design rather than additional components.
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
Reduces manufacturing and installation time while ensuring a watertight seal around fixtures, providing an aesthetically pleasing finish.
Implementation Method 1
a first plate segment that is rotatable with respect to a second plate segment between open and closed positions... A living hinge system is integral with and rotatably joins the two plate segments
Implementation Method 2
integrally formed from a resilient thermoplastic polymer
Data Source
AI summary
A split block assembly includes a backplate with an outwardly projecting mounting flange that mounts to a wall structure such that the flange is interposed between a siding panel and the wall structure. The backplate includes first and second plate segments rotatable with respect to each other between an open position, whereat the first plate segment is spaced from the second plate segment, and a closed position, whereat the plate segments abut and thereby cooperatively define a hole that receives therethrough a fixture. A living hinge system is integral with and rotatably joins the two plate segments. The living hinge system includes a first living hinge adjoining the first plate segment and bending on a first axis, a second living hinge adjoining the second plate segment and bending on a second axis oblique to the first axis, and a flap extending between and joining the two living hinges.