Wall Box Mounting Latching Mechanism for Skew Compensation
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Solution Overview
Problem
Existing wall box mounting systems face issues such as skewed installations leading to aesthetic problems, insufficient screw length for deep mountings, cross-threading, and improper device orientation affecting device performance, especially for devices like infrared receivers.
Innovation Solution
A base plate with a latching mechanism featuring magnetic and frictional engagement to securely attach devices to a wall box, allowing for proper alignment and secure mounting without screws, using magnets and adjustable components to ensure proper orientation and secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional screw mounting is used to attach devices to wall boxes, then secure attachment can be achieved, but cross-threading occurs when the wall box is not parallel to the wall surface, leading to mounting failure
Solution Approach 1:
The patent replaces the traditional screw-threaded mechanical fastening system with a friction-based clamp mechanism. The clamp applies radial pressure to the wall box through friction contact, eliminating the need for threaded holes and preventing cross-threading issues that occur when wall boxes are not perfectly parallel to the wall surface.
Solution Approach 2:
The invention changes the mounting parameter from rigid threaded engagement to flexible frictional contact. The clamp mechanism can accommodate variations in wall box alignment by adjusting the contact pressure and angle, allowing successful mounting even when the wall box is not perfectly parallel to the wall.
2Shape
If wall boxes are mounted deeply in the wall, then aesthetic appearance is improved, but supplied screws become too short to affix devices to the wall box
Solution Approach 1:
The clamp mechanism transitions from linear screw engagement to radial pressure application. By clamping around the exterior of the wall box, the system accesses the mounting function in a different dimensional space, eliminating the need for long screws that would be required to reach through deep wall box installations.
3Adaptability or versatility
If wall boxes are mounted with potential skew, then installation flexibility is improved, but the resulting light switch or device appears skewed, creating aesthetic problems
Solution Approach 1:
The clamp mechanism introduces dynamic adjustability to the mounting system. The clamp can be positioned and adjusted to compensate for wall box skew, allowing the installer to achieve proper device alignment and aesthetic appearance while maintaining the flexibility to accommodate various wall box installation angles and positions.
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 ensures proper alignment and secure attachment of devices within the wall box, preventing cross-threading and aesthetic issues, while allowing for easy adjustment and secure positioning, even if the wall box is not perfectly parallel to the wall.
Implementation Method 1
The latching mechanism includes a frictional engagement member configured to frictionally engage with the wall box upon insertion into the wall box
Implementation Method 2
A base plate with a latching mechanism featuring magnetic and frictional engagement to securely attach devices to a wall box
Data Source
AI summary
An apparatus and method for mounting a device in a wall box is provided. The apparatus includes a base plate formed by a front portion and a plurality of side portions extending to the rear to define a substantially open rear portion, and a latching mechanism coupled to the base plate. The front portion is connected to the device. The base plate is configured to be at least partially inserted into the wall box. The latching mechanism includes a frictional engagement member configured to frictionally engage with the wall box upon insertion into the wall box.