Adjustable Junction Box and Hanger Bars for Compact Recessed Lighting
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Solution Overview
Problem
Traditional recessed lighting systems are bulky and difficult to adjust due to separate mounting of drivers and light sources, requiring additional hardware and complicating installation and maintenance.
Innovation Solution
A compact recessed lighting system with a unified casting housing both the light source module and driver, allowing for adjustment and installation without separate compartments, using hangar bars and holders for flexible positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If drivers and light sources are mounted separately in traditional recessed lighting systems, then each component can be independently installed and maintained, but the overall system becomes bulky and installation becomes more complex requiring additional hardware
Solution Approach 1:
The patent combines the driver and light source into a single integrated housing unit, eliminating the need for separate mounting of these components. This merging reduces the number of parts and hardware required for installation while simplifying the overall system structure, directly addressing the contradiction between ease of installation and system complexity
2Reliability
If separate compartments are used for drivers and light sources, then each component has its own dedicated space, but the system becomes bulkier and requires more installation hardware
Solution Approach 1:
The driver and light source are integrated into a single housing unit that provides dedicated spaces for each component while maintaining their functional separation. This approach reduces the overall system volume compared to separate compartment designs while ensuring each component has its own protected space, thus resolving the contradiction between component stability and system volume
3Strength
If traditional separate mounting methods are used, then components can be securely fixed, but adjustment and repositioning become difficult and time-consuming
Solution Approach 1:
The patent incorporates adjustable positioning mechanisms that allow the integrated housing to be easily moved and repositioned after initial installation. These dynamic features enable simple adjustment while maintaining secure mounting, resolving the contradiction between mounting strength and ease of adjustment by allowing the system to transition from a fixed to an adjustable state as needed
Data Source
AI summary
A junction box having a cavity to contain electrical wires that provide a connection to a building mains voltage from an electrical system of a building is coupled to a plurality of telescoping hanger bars to hold the junction box in a wall or ceiling in the building. Each telescoping hanger bar is extendible and/or retractable to vary a length of the hanger bar. A position of the junction box is adjustable along the length of each telescoping hanger bar. In one example, the apparatus does not include a can, separate from the junction box, to contain a lighting device of a recessed lighting assembly.