Adjustable Hangar Bar Assembly for Stable Recessed Luminaire Mounting

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional hangar bar assemblies for recessed luminaires lack adjustable length without disassembly and suffer from instability, particularly in fully-extended positions, and are often limited to specific ceiling configurations.

Innovation Solution

A hangar bar assembly comprising a first and second member with attachment structures, including elongated slots and retaining projections, allowing for adjustable length without disassembly and enhanced stability through friction fit fasteners and reinforcing bridges, enabling secure attachment to various support structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional one-piece hangar bars are used, then structural rigidity is maintained at low cost, but length adjustability is lost and installation is limited to standard joist spacings

Engineering Contradiction:

Improvelength adjustabilityVSAvoidbar configuration

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The hangar bar is divided into two separate members: a first hangar bar member with an elongated slot and a second hangar bar member with retaining projections. This segmentation allows the members to be adjusted relative to each other along the slot to achieve different lengths, providing adaptability while maintaining structural integrity through the interconnected design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The hangar bar assembly transitions from a fixed one-piece structure to a dynamic two-piece configuration where the second member can slide along the elongated slot of the first member. This dynamic arrangement enables length adjustment by moving the second member to different positions along the slot, allowing adaptation to various joist spacings.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If two-piece hangar bar assemblies are used, then length adjustability is achieved, but stability and support adequacy are reduced especially in fully-extended positions

Engineering Contradiction:

Improvelength adjustabilityVSAvoidhangar stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The retaining projections on the second hangar bar member are designed with curved surfaces that engage with the elongated slot. This curved geometry provides gradual engagement and distribution of loads along the contact surface, enhancing stability while allowing smooth adjustment of the hangar bar length.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The hangar bar assembly combines two different member designs with complementary features: the first member provides a stable base with the elongated slot, while the second member with retaining projections adds adjustability. The composite structure of these two members working together achieves both length variability and structural stability.

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If two-piece hangar bars are disassembled for length adjustment, then adaptability to different joist spacings is achieved, but installation time and complexity increase

Engineering Contradiction:

Improvelength adjustabilityVSAvoidinstallation ease

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The hangar bar assembly allows dynamic adjustment of length by sliding the second member along the elongated slot of the first member while installed. This eliminates the need for disassembly before adjustment, as the design inherently accommodates length changes through the slot-projection interface that can be repositioned without removing the hangar from the joists.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The elongated slot and retaining projections are designed to self-align and self-retain the second member at various positions along the first member. The retaining projections naturally engage with the slot at appropriate spacing intervals, providing self-positioning functionality that simplifies adjustment without requiring precise measurement or complex alignment procedures.

Inventive Principle:

Principle #25Self-service

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 provides a stable and adjustable hangar bar assembly that can be easily extended or shortened to fit different joist spacings without disassembly, offering improved support and versatility across various ceiling configurations.

Implementation Method 1

friction fit fasteners

Methodology Applied

Scientific EffectFriction fit: Friction

Data Source

PatentUS7673841B2Hangar bar for recessed luminaires with integral nail

Publication Date: 2010.03.09 SIGNIFY HOLDING BV

AI summary

A hangar bar assembly for a recessed luminaire is disclosed. The hangar bar assembly includes a first hangar bar member having a first attachment structure disposed on an end thereof, and a second hangar bar member having a second attachment structure disposed on an end thereof, the second hangar bar member being adjacent to the first hangar bar member. The first and the second attachment structures each include a first wall having a first fastener aperture and a second wall having a second fastener aperture, the first and second fastener apertures being formed about a common central longitudinal axis.