Adjustable Hanger Bar Slot Bushing Joist Mount
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Solution Overview
Problem
The installation of recessed lighting fixtures is challenging due to difficulties in positioning and securing hanger bars between ceiling joists, as traditional methods require precise placement of nails, which can be hard to manage and adjust during the installation process.
Innovation Solution
A hanger bar design featuring attaching plates with elongate slots and bushings allows for initial partial attachment and subsequent adjustment by moving the attaching plates within the slots, enabling precise positioning and secure fastening to the joists.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional nails are used to attach hanger bars to joists, then the attachment is secure, but the installer cannot easily adjust the position of the hanger bar after initial placement
Solution Approach 1:
The attaching plate is segmented into a plate body and an extended portion with a slot, creating distinct functional zones that enable both secure attachment and adjustable positioning
Solution Approach 2:
The system transitions from a static nailed attachment to a dynamic adjustable system where the attaching plate can move along the slot relative to the bushing, allowing position changes before final attachment
2Productivity
If the installer uses a hammer to drive nails through flange openings, then the hanger bar can be attached to joists, but the installer must hold the hanger bar and nail simultaneously making the process difficult
Solution Approach 1:
The fastener is pre-positioned within the bushing before attachment, eliminating the need to hold and coordinate multiple components during installation
Solution Approach 2:
The attaching plate with slot and bushing assembly is self-aligning and self-positioning, allowing the fastener to guide the attachment process without requiring the installer to manually position multiple elements
3Manufacturing precision
If the flange is placed too high or too low relative to the bottom of the joist, then the nail must be pulled out for reinstallation, but a fully seated nail is difficult to grasp for removal
Solution Approach 1:
The slot-bushing-fastener assembly creates a dynamic positioning system that allows the attaching plate to be adjusted to the correct position before final attachment, preventing positioning errors
Solution Approach 2:
The bushing acts as an intermediary between the slot and the fastener, providing a controlled interface that guides the fastener and enables precise positioning during adjustment
Data Source
AI summary
A hanger bar attachable between joists for supporting a fixture has an attaching plate at distal ends with a contact portion for bearing against a joist and a laterally extending portion that defines a recess. The extended portion defines an elongate slot that receives a bushing and a fastener extends through the bushing for securing the elongate bar to the joist. The hanger bar is selectively positionable after initial attachment to the joist by moving the attaching plate as guided by the bushing in the slot. A method of attaching a hanger bar to joists for supporting fixtures is disclosed.