Adjustable Torsion Spring Receiver for LED Retrofit Mounting
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Solution Overview
Problem
Existing methods for replacing recessed down-lighting fixtures with LED fixtures face difficulties due to non-uniform pull force and the need for excessive work, such as drilling, caused by adapter bands that require housing installation and torsion spring misalignment, leading to off-centered mounting and sagging issues.
Innovation Solution
A retrofit receiver assembly with horizontal and vertical adjustment capabilities that clamps to the rough-in section and ceiling hole, using torsion spring receivers to maintain proper pull force and accommodate various ceiling thicknesses and diameters without the need for additional housing or drilling, ensuring easy installation and flush mounting of LED luminaires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If adapter bands with housing installation are used for mounting retrofit assemblies, then mounting capability is provided, but device complexity and installation work increase due to required housing installation and drilling
Solution Approach 1:
The patent removes the adapter band and housing components from the mounting system, extracting only the essential function of mounting the LED luminaire directly to the ceiling opening. The receiver assembly consists of simple brackets that attach directly to the ceiling edges without requiring separate housings or complex adapter bands, thereby eliminating drilling and housing installation steps.
Solution Approach 2:
Instead of mounting the LED luminaire to a housing that is then mounted to the ceiling (traditional approach), the patent inverts the approach by mounting the receiver brackets directly to the ceiling edges and attaching the luminaire to the receiver assembly. This eliminates the intermediate housing component and simplifies the overall mounting structure.
2Device complexity
If torsion spring receivers are fixed at specific positions on adapter bands, then mounting structure is simplified, but mounting precision deteriorates causing off-centered mounting and non-uniform pull force
Solution Approach 1:
The patent makes the receiver assembly dynamic by allowing adjustment of the torsion spring receiver positions along the brackets. The receivers can be positioned at different locations depending on the ceiling opening dimensions and thickness, enabling proper centering and uniform pull force distribution. This adjustability resolves the contradiction between structural simplicity and mounting precision.
3Device complexity
If fixed-position receiver brackets are used, then device complexity is reduced, but adaptability deteriorates for varying ceiling thicknesses and aperture diameters
Solution Approach 1:
The receiver brackets are designed with adjustable features that allow the position and orientation of the brackets to be modified according to different ceiling opening sizes and thicknesses. This dynamic adjustability enables the same simple bracket structure to adapt to various ceiling conditions without increasing overall device complexity.
Solution Approach 2:
The patent allows adjustment of key parameters including the position of receiver brackets along the ceiling edges, the angle of bracket attachment, and the location of torsion spring receivers. By changing these parameters, the system can accommodate different ceiling thicknesses and aperture diameters while maintaining a relatively simple bracket structure.
4Ease of operation
If adapter bands requiring housing installation are used, then mounting capability is provided, but installation time increases due to excessive work requirements
Solution Approach 1:
The patent extracts and eliminates the time-consuming housing installation and drilling steps from the mounting process. The receiver brackets are designed to be directly attached to the ceiling edges using simple fasteners, and the LED luminaire is directly mounted to the receiver assembly without requiring adapter bands or intermediate housings, significantly reducing installation time.
Solution Approach 2:
The receiver brackets are pre-configured with attachment features that align with standard ceiling opening dimensions, allowing for quick installation without the need for custom fitting or extensive drilling. The design anticipates common ceiling variations and incorporates adjustment capabilities that enable rapid adaptation during installation.
Data Source
AI summary
A retrofit assembly for inserting LED luminaries into previously recessed lighting fixtures has a horizontal bridge adjustable for various existing opening diameters of ceiling holes. The horizontal bridge carries two vertically adjustable brackets at its opposing ends. Tabs on the end plates of the bridge and tabs on the vertically adjustable brackets together help form bolt-operated vertical clamps adjustable for various ceiling thicknesses. The vertically adjustable brackets also carry torsion spring receivers for accepting the torsion springs of a retrofit LED luminaire/trim assembly. The vertically adjustable brackets may be spring-loaded for ease of adjustment when increasing the dimension of the vertical clamps.