Toggle Switch Retrofit Remote With Faceplate Barb Mounting
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Solution Overview
Problem
Existing load control systems require electrical re-wiring and replacement of mechanical switches for installing load control devices, making it difficult for average consumers to install these devices without professional assistance.
Innovation Solution
A remote control device that can be mounted over a mechanical switch's actuator, allowing for wireless control of electrical loads without re-wiring, by using a base portion that secures the toggle actuator in the on position and includes a wireless communication circuit for transmitting control signals to the load control device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a load control device replaces a standard switch, then control functionality and energy savings are improved, but installation complexity and difficulty increase due to required electrical re-wiring
Solution Approach 1:
The remote control device is mounted over the existing mechanical switch assembly, nesting the new control functionality within the existing switch infrastructure. The base portion fits over the switch housing while the actuator engages the existing toggle actuator, allowing the new device to utilize the existing mechanical structure rather than requiring complete replacement and re-wiring.
Solution Approach 2:
The remote control device acts as an intermediary between the user and the electrical load. Instead of directly replacing the switch, it interfaces with the existing switch mechanism through the actuator engagement, translating user input into switch actuation while adding wireless control capabilities without requiring electrical re-wiring.
2Adaptability or versatility
If a load control device replaces a standard switch, then advanced control features are improved, but ease of installation deteriorates due to professional assistance requirements
Solution Approach 1:
The device enables average consumers to perform the installation themselves without requiring professional electrical contractors. The mounting structure is designed to be attached to the existing switch housing using simple mechanical fastening methods that do not require electrical wiring skills, allowing end-users to install the device independently.
Solution Approach 2:
The device is divided into distinct functional components: a base portion for mounting to the switch housing, an actuator for engaging the toggle actuator, and a control portion with wireless communication circuitry. This segmentation allows each component to be optimized independently and simplifies the installation process by separating the mechanical mounting functions from the electrical control functions.
3Ease of manufacture
If a remote control device is mounted over a mechanical switch, then re-wiring requirements are reduced, but mounting stability may worsen due to attachment challenges
Solution Approach 1:
The mounting structure is designed to be attached to the switch housing before the device is fully assembled and before any operational use. The mounting structure includes pre-positioned attachment features that engage with corresponding features on the switch housing, ensuring stable mounting is established prior to device operation.
Solution Approach 2:
The mounting structure utilizes asymmetric attachment features including tabs that engage with slots in the switch housing, creating a secure fit that prevents removal in the wrong direction. The actuator is designed with an asymmetric engagement mechanism that fits into a corresponding asymmetric receptacle, ensuring proper orientation and stable mechanical coupling.
Data Source
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AI summary
A remote control device may be configured to be mounted over the toggle actuator of a light switch and to control a lighting load. The remote control device may comprise a base portion having planar extensions removably attached or affixed thereto. The planar extensions may be adapted to be received in a gap between a faceplate of the light switch and the toggle actuator for holding the remote control device against the faceplate. The planar extensions may comprise barbs that allow for insertion of the extensions in the gap, but may bite into the faceplate to hinder removal of the remote control device. The planar extensions may be defined by a mounting structure that is configured to be disposed between a yoke of the mechanical switch and the faceplate, and that protrudes beyond a front surface of the faceplate.