Angled Support Clip for Single-Handed Ballast Housing Installation
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Solution Overview
Problem
Conventional lighting fixtures with ballast tank housings pose difficulties during maintenance and installation due to the weight of the housing, which can lead to safety hazards, especially when securing the housing to a mounting module from hazardous locations.
Innovation Solution
The use of support clips with a web, lower flange, and upper flange, where the upper flange extends at an angle to engage the mounting module, allowing the clip to support the weight of the housing and enable secure fastening with a single hand, reducing the need for two-handed operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional locking mechanism is used to secure the ballast tank housing to the mounting module, then the housing can be securely fastened, but the user must use both hands to support the housing and tighten the locking screw, which is difficult when the housing weighs up to 50 pounds and poses safety hazards
Solution Approach 1:
The locking mechanism is divided into two independent functional components: a support clip that mechanically holds the housing weight, and a separate locking screw that secures the connection. This segmentation allows the support function and locking function to be performed independently, enabling single-handed operation while maintaining safety.
Solution Approach 2:
The support clip acts as an intermediary component between the housing and the mounting module. It provides mechanical support for the housing weight through its engagement with the mounting module's opening, freeing the user's hands from supporting the housing during the locking process.
2Productivity
If the user supports the heavy housing with one hand while tightening the locking screw with the other, then the housing can be secured, but the process is slow and requires two-handed operation which is unsafe from ladders or hazardous locations
Solution Approach 1:
The support clip is pre-installed on the housing before the locking process begins. This preliminary action establishes the mechanical support structure in advance, so that when the user approaches the housing, the support function is already active, allowing immediate single-handed locking without needing to manually support the housing first.
3Loss of time
If a simple fastening mechanism is used, then the installation is quick, but the housing may swing open or become insecure under heavy weight
Solution Approach 1:
The solution merges two fastening mechanisms into a single system: the support clip provides mechanical retention and weight support, while the locking screw provides secure fastening. Both mechanisms work together on the same connection interface, combining their strengths to provide both quick installation and secure holding capability.
Solution Approach 2:
The support clip features a curved or contoured engagement surface that conforms to the mounting module's opening geometry. This curvature provides natural mechanical interference and retention, preventing the housing from swinging open while maintaining quick installation through simple snap-in or slide-in engagement.
Data Source
AI summary
Support clips and systems thereof are provided. Support clips include a web, a lower flange, and an upper flange. The lower flange extends from the web orthogonally. The upper flange extends from the web, towards the lower flange, at an angle. The lower flange includes an aperture for receiving a fastener. Systems include support clips of the present invention coupling a ballast housing to a mounting module. The lower flange is secured to the housing, and the upper flange engages the mounting module, such that the housing is supported by the support clip against the mounting module when in a latched position. A user is able to secure a fastener through the support clip aperture and openings in the housing and mounting module without having to use additional hands.