Suspended Ceiling Light Fixture Assembly for Faster Installation
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Solution Overview
Problem
The assembly of lighting fixtures in suspended ceilings is time-consuming and costly due to the individual installation of junction boxes, network interfaces, and other components, which affects the overall project cost and aesthetic finish.
Innovation Solution
A light fixture assembly that connects directly to a ceiling system, featuring a tray with couplers and a coupling assembly for easy integration with cross members, allowing for preassembled installation and a consistent aesthetic finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If individual components (junction boxes, network interfaces) are installed separately in suspended ceilings, then flexibility in component selection and installation location is improved, but labor time and installation cost increase significantly
Solution Approach 1:
The patent combines multiple individual components (junction box, network interface, light fixture) into a single integrated ceiling assembly unit. This merging allows all components to be installed simultaneously as one unit rather than separately, reducing installation time while maintaining the ability to select different component configurations to meet various project requirements.
Solution Approach 2:
The ceiling assembly is pre-assembled with all necessary components (junction box, network interface, light fixture) integrated together before installation. This preliminary assembly allows electricians and tradesmen to install the complete functional unit in one operation, eliminating the need for sequential individual installations and significantly reducing on-site labor time.
2Adaptability or versatility
If individual components are assembled separately on site, then adaptability to different ceiling configurations is improved, but aesthetic finish and control over fit and finish deteriorate
Solution Approach 1:
By merging all components into a single integrated ceiling assembly, the patent ensures that all parts are precisely fitted together during manufacturing under controlled conditions. This produces a clean, uniform aesthetic finish that is difficult to achieve when components are assembled separately on-site by different tradesmen with varying skill levels.
Solution Approach 2:
The integrated ceiling assembly presents a homogeneous, unified appearance from the ceiling underside, with all components (junction box, network interface, light fixture) seamlessly integrated. This eliminates the visual discontinuities and varying finish qualities that result from separate component installations, providing a consistent aesthetic throughout the ceiling.
3Adaptability or versatility
If multiple individual components are installed separately, then component functionality and versatility are improved, but overall project cost increases
Solution Approach 1:
The patent merges multiple components into a single integrated assembly that maintains all individual component functionalities (electrical junction box, network interface, light fixture). By combining these functions into one unit, the patent reduces installation labor costs, minimizes the number of tradesmen required, and streamlines the installation process, thereby reducing overall project costs while preserving full component functionality.
Solution Approach 2:
The integrated ceiling assembly serves multiple functions simultaneously - electrical distribution, network connectivity, and lighting - all within a single installed unit. This multi-functionality eliminates the need for separate installations of each component type, reducing both material handling and labor costs while maintaining the versatility and adaptability of having all these functional components available in the ceiling.
Data Source
AI summary
A ceiling assembly includes a first cross member, a second cross member spaced apart from and parallel to the first cross member and a plurality of light fixtures. Each light fixture includes an elongated tray comprising a base comprising a first side, a second side and a first opening therethrough. The elongated tray further includes a first longitudinally extending wall extending from the second side of the base and a second longitudinally extending wall extending from the second side of the base. The first longitudinally extending wall has a first coupler. The second longitudinally extending wall has a second coupler. The light fixture assembly has a light assembly and a coupling assembly coupling the light assembly to the tray. The coupling assembly is positioned around the opening and adjacent to the second side around the first opening. A baffle is coupled within the coupling assembly and comprises a lower edge.