Surface-Mount Electrical Installation Snap-Fit Locking Assembly
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Solution Overview
Problem
Existing electrical installation devices for surface mounting require significant installation space, are cumbersome to assemble with screw connections, and necessitate tools, increasing the risk of losing parts and manufacturing effort.
Innovation Solution
The use of an elastic locking arm on the mounting plate that projects perpendicularly to the mounting direction, integrating functional and housing locking hooks to secure the functional insert and housing without screws, allowing tool-free assembly and enhanced holding force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a screw connection is used to lock the functional insert and housing to the mounting plate, then the assembly can withstand high pull-off forces, but the assembly requires tools, increases the risk of losing parts, and increases manufacturing effort
Solution Approach 1:
The patent replaces the screw connection mechanical system with a snap-fit locking mechanism. The housing and functional insert feature locking protrusions that engage with corresponding locking recesses in the mounting plate, eliminating the need for screws and tools while maintaining structural integrity and resistance to pull-off forces.
Solution Approach 2:
The snap-fit locking mechanism is designed to be self-aligning and self-locking. The locking protrusions automatically engage with the locking recesses when the housing and functional insert are mounted, providing tool-free assembly that is both easy to perform and capable of withstanding high forces without additional fastening components.
2Reliability
If a screw connection is used to lock the functional insert and housing, then the connection is secure, but the assembly process becomes cumbersome and requires tools
Solution Approach 1:
The patent substitutes the complex screw connection system with a simple snap-fit mechanism. The locking protrusions and recesses provide secure connections through elastic deformation and geometric interlocking, achieving reliable fixation without the complexity of threaded fasteners, tool requirements, and multiple assembly steps.
Solution Approach 2:
The invention extracts the essential locking function from the screw connection system, retaining only the geometric interlocking aspect through locking protrusions and recesses. This eliminates the need for threaded elements, washers, and other accessory components, simplifying the overall device while maintaining connection security.
3Ease of operation
If pre-assembled screws are used on components, then assembly is improved, but a tool is still required and manufacturing effort increases
Solution Approach 1:
The patent replaces the pre-assembled screw system with an integrated snap-fit mechanism where locking protrusions are formed directly as part of the housing and functional insert structures. This eliminates the need for separate screw components and pre-assembly operations, reducing manufacturing steps while enabling tool-free final assembly.
Solution Approach 2:
The locking functionality is merged into the structural design of the housing and functional insert themselves. The locking protrusions are formed as integral features during the molding or fabrication process, combining the structural and fastening functions into a single manufacturing step rather than requiring separate fastener components and assembly operations.
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 minimizes assembly effort, reduces the need for loose components, and provides high withdrawal forces, ensuring easy installation and maintenance accessibility while maintaining structural integrity.
Implementation Method 1
The mounting plate has at least one locking arm which projects perpendicularly to the mounting direction and is elastic
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention relates to an electrical installation device (1) for surface mounting, comprising a housing (2), a functional insert (4), and a mounting plate (6) which can be arranged on a bearing surface. The mounting plate (6) has a support surface (8) facing in a mounting direction (M) for engagement with the bearing surface. The functional insert (4) and the housing (2) can be mounted opposite the support surface (8) on the mounting plate (6) facing in the mounting direction (M) in an assembled state of the electrical installation device (1) in such a way that, in the assembled state of the electrical installation device (1), the housing (2) surrounds the functional insert (4) with a housing wall (12) perpendicular to the mounting direction (M), and the housing (2) and the functional insert (4) are locked to the mounting plate (6) against movement counter to the mounting direction (M).The mounting plate (6) has at least one elastic locking arm (16) projecting against the mounting direction (M) and perpendicular to the mounting direction (M), which, in the mounted state of the electrical installation device (1), extends between the housing wall (12) and the functional insert (4) and locks the functional insert (4) by means of at least one functional locking hook (18) pointing towards the functional insert (4) and the housing (2) by means of at least one housing locking hook (20) pointing towards the housing wall (12).