Wireless Wallbox Dimmer Structure for Modular Buttons and Stable Range
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Solution Overview
Problem
Existing wireless wallbox dimmers have limited flexibility in accommodating various button configurations and installation environments, and they often require specific internal components, which can lead to functional issues due to yoke distortion during installation and a lack of modularity in housing semiconductor power devices.
Innovation Solution
A load control device with a universal structure featuring a metal yoke, a two-loop antenna, and a cradle that supports a variable number of controllably conductive devices, allowing for interchangeable button assemblies and independent support of the button assembly, along with a faceplate that enhances wireless transmission range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different button configurations are used in wallbox dimmers, then various button assemblies must be manufactured, but different internal components (antennas, yokes, cradles, PCBs) must also be manufactured specifically for each button assembly
Solution Approach 1:
The patent applies universality by designing a standardized yoke structure with a universal antenna and cradle that can accommodate multiple button configurations. The yoke includes a standardized mounting interface and the antenna is positioned to work with various button assemblies, allowing one set of internal components to support multiple button configurations rather than requiring dedicated components for each configuration.
Solution Approach 2:
The patent segments the button assembly from the internal components by providing independent mounting interfaces. The button assembly can be attached to the yoke through standardized mounting holes and interfaces, allowing the button assembly to be replaced or configured independently while the core internal components (yoke, antenna, cradle, PCB) remain the same.
2Device complexity
If the button assembly is supported directly by the yoke, then the structure is simple, but the yoke may warp during installation causing buttons to become nonfunctional
Solution Approach 1:
The patent introduces a cradle as an intermediary component between the button assembly and the yoke. The cradle is attached to the yoke and provides a stable mounting platform for the button assembly. This intermediary structure prevents direct stress transmission from the yoke to the button assembly during installation, preventing yoke warping from affecting button functionality while maintaining structural support.
3Strength
If the yoke is over tightened during installation, then the dimmer is securely mounted, but the yoke becomes distorted causing functional issues
Solution Approach 1:
The patent incorporates compliance features in the mounting structure, including flexible mounting holes and stress-absorbing elements in the yoke design. These features are built into the structure beforehand to accommodate installation variations and prevent over-tightening damage. The mounting interface is designed to distribute stress evenly, preventing localized deformation that would occur with direct rigid mounting.
4Volume of stationary object
If only one or two semiconductor power devices are housed in the dimmer, then the device size is manageable, but the dimmer lacks flexibility for different power requirements
Solution Approach 1:
The patent implements a modular semiconductor mounting system where the number and arrangement of semiconductor power devices can be dynamically configured based on power requirements. The PCB and mounting structure are designed to accommodate variable numbers of devices (one, two, or more), allowing the dimmer to be adapted to different power applications without changing the overall housing size significantly. The flange and mounting holes are positioned to support flexible device configurations.
Data Source
AI summary
A provided wireless wallbox dimmer may accommodate a plurality of button configurations. The dimmer may be configured to contain a variable number of controllably conductive devices. The dimmer may include a yoke that defines a first plane and an antenna that defines a second plane that is substantially parallel to and spaced apart from the first plane. The yoke may have a flange that is oriented angularly offset relative to the first plane and provides a plurality of mounting locations for controllably conductive devices. The antenna may provide the dimmer with a first wireless transmission range. The dimmer may include a faceplate that cooperates with the antenna to provide the dimmer with a second wireless transmission range that is broader than the first wireless transmission range. The dimmer may include a button assembly that is supported independently of the yoke.