Adjustable Plaster Frame for Recessed Luminaires
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Solution Overview
Problem
Current plaster frames for recessed lighting luminaires require multiple models with fixed hole sizes, leading to surplus and shortfall issues due to varying luminaire sizes, necessitating OEMs to stock a multitude of different hole sizes and resulting in inefficient inventory management.
Innovation Solution
An adjustable plaster frame with a variable main hole size and shape, utilizing moving leaves and an actuating ring to change the aperture size, allowing for multiple geometric shapes without the need for fasteners, and incorporating graduations for precise adjustment and locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple plaster frame models with different fixed hole sizes are stocked, then all luminaire sizes can be accommodated, but inventory complexity and storage costs increase
Solution Approach 1:
The patent applies the dynamics principle by transforming the static fixed hole into a dynamic adjustable opening. The plaster frame incorporates movable leaves that can be repositioned to change the opening size and shape, allowing a single frame to adapt to different luminaire dimensions. This eliminates the need to stock multiple fixed-size frames while maintaining versatility across various luminaire types.
Solution Approach 2:
The patent implements universality by designing a single plaster frame model that can serve multiple functions - accommodating round, square, and rectangular luminaires of various sizes. The adjustable opening mechanism enables one frame to replace multiple specialized frames, creating a universal solution that reduces inventory complexity while maintaining broad adaptability.
2Adaptability or versatility
If a single plaster frame with a large fixed hole is used, then all luminaire sizes can be accommodated, but the hole cannot be precisely matched to smaller luminaires
Solution Approach 1:
The movable leaves can be positioned at different intervals along the frame, allowing the opening size to be dynamically adjusted to precisely match the specific luminaire dimensions. This dynamic adjustment capability enables precise hole sizing for each installation while maintaining the ability to accommodate larger luminaires when needed.
Solution Approach 2:
The frame is segmented into multiple movable leaves that can be independently positioned. This segmentation allows for fine-grained adjustment of the opening size, enabling precise matching to smaller luminaires while maintaining the overall structure's capacity to accommodate larger fixtures when the leaves are positioned to create a larger opening.
3Device complexity
If reducer rings or plates are used to reduce hole size, then a single large plaster frame can be stocked, but additional components and assembly steps are required
Solution Approach 1:
The patent merges the function of the plaster frame and the reducer elements into a single integrated structure. The adjustable leaves are built-in components of the frame itself, eliminating the need for separate reducer rings or plates. This integration simplifies the overall system by combining multiple functions into one unit, reducing both inventory requirements and assembly complexity.
Solution Approach 2:
The patent extracts the hole-size adjustment function from separate reducer components and incorporates it directly into the plaster frame structure. By taking out the reduction function and integrating it into the frame's movable leaves, the design eliminates the need for additional reducer rings or plates, simplifying both inventory management and assembly procedures.
4Adaptability or versatility
If an adjustable mechanism is added to the plaster frame, then hole size flexibility increases, but device complexity and cost increase
Solution Approach 1:
The patent introduces dynamic adjustability through movable leaves that can be repositioned along the frame. This dynamic mechanism provides hole size flexibility while maintaining relatively simple construction, as the leaves utilize basic mechanical principles of movement and positioning rather than complex actuation systems.
Solution Approach 2:
The patent achieves adaptability by enabling parameter changes in the opening size and shape through the movable leaves. The mechanism allows continuous adjustment of dimensional parameters without requiring complex systems, simply by repositioning the leaves to different locations along the frame structure.
Data Source
AI summary
A plaster frame is provided for recessed lighting luminaires, wherein the main hole size is not fixed, but adjustable, and in more than one shape opening, e.g. round, square, rectangular, and other opening shapes as required. The plaster frame has an adjustable hole, the concept here disclosed comprises a series of moving leaves and may also contain an actuating ring, the rotation of which cause the leaves to move inward or outward, changing the hole, or aperture. Although fasteners may be used to retain the various moving elements, these adjustable openings can also be utilized without the use of any fasteners.