Adjustable Junction Box for Recessed Ceiling Installation
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Solution Overview
Problem
Existing junction boxes are not vertically adjustable with respect to hanger-bars and ceilings, leading to increased installation times due to the need for custom measurements for different ceiling thicknesses and spacings between joists and ceilings.
Innovation Solution
A system of hanger-bar-to-box-attachment-devices that allow for vertical and horizontal adjustment of junction boxes, using slidable and lockable mechanisms along defined paths, with height markings on the junction box for precise positioning, minimizing the need for holes or breaches and enabling quick, efficient installation across a range of ceiling thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fixed-position junction boxes are used, then installation is simple for a specific ceiling thickness, but installation time increases for different ceiling thicknesses due to custom measurements
Solution Approach 1:
The junction box is made dynamically adjustable through a sliding mechanism with multiple pre-marked positions. The box can slide vertically along the hanger-bar within a defined range, allowing installers to quickly select the appropriate position for different ceiling thicknesses without custom measurements or repositioning.
Solution Approach 2:
The system provides discrete parameter changes through pre-marked height positions on the hanger-bar. These markings correspond to different ceiling thicknesses, allowing the junction box position to be adjusted in predetermined increments rather than requiring continuous measurement and positioning.
2Manufacturing precision
If custom measurements are taken for each ceiling, then precise recessed positioning is achieved, but installation complexity increases
Solution Approach 1:
The hanger-bar is pre-marked with height positions corresponding to different ceiling thicknesses before installation. This preliminary preparation eliminates the need for on-site measurements and calculations, as installers simply need to select the appropriate pre-marked position that matches their ceiling thickness.
Solution Approach 2:
The system uses simple, inexpensive height markings on the hanger-bar instead of complex measurement tools or adjustable mechanisms. These markings are permanent but simple to implement, providing precise positioning guidance without adding mechanical complexity to the installation process.
3Reliability
If hanger-bars are attached to proper locations on joists, then desired recessed positioning is achieved, but adaptability to different ceiling configurations is reduced
Solution Approach 1:
The junction box is made dynamically adjustable through a sliding mechanism with multiple pre-marked positions. The box can slide vertically along the hanger-bar within a defined range, allowing installers to quickly select the appropriate position for different ceiling thicknesses without custom measurements or repositioning.
Data Source
AI summary
A system for adjusting a junction box, to be recessed with respect to a ceiling, between a minimum ceiling thickness and a maximum ceiling thickness, utilizes a pair of hanger-bar-to-box-attachment-devices that are attached to both the junction box and to a pair of hanger-bars. The pair of hanger-bar-to-box-attachment-devices are attached to the junction box in an adjustable manner that is vertically slidable and lockable along a finite vertical path. And the pair of hanger-bar-to-box-attachment-devices that are also attached to the pair of hanger-bars, are adjustable in a horizontally slidable and lockable manner along a finite horizontal path, defined by a length of the pair of hanger-bars. The junction box may also have a set of height-markings on its exterior to facilitate adjusting the junction box to a desired height with respect to a given ceiling.