Compact Junction Box with Flexible Conduit for Recessed Lighting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing recessed lighting fixtures face challenges in accessing junction boxes due to tight joist spacing and obstructions, making installation and removal difficult, especially when the junction box is miniaturized to fit through small ceiling openings, and require additional labor for remote component mounting.
Innovation Solution
A compact junction box assembly with a cylindrical housing and axially extending support, featuring a releasable side wall and resiliently biased stop for easy access, along with a flexible tether to prevent strain on wiring and conduit, allowing for secure attachment to a lamp housing via a flexible conduit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the junction box is miniaturized to fit through small ceiling openings, then the fixture can be installed in tight spaces, but access to the junction box for wiring becomes difficult
Solution Approach 1:
The junction box is divided into multiple compartments separated by a chassis with dividers. This segmentation allows compact wiring organization while maintaining access to specific areas through the flexible conduit connection, resolving the conflict between miniaturization and accessibility.
Solution Approach 2:
A flexible conduit acts as an intermediary connection between the lamp housing and the miniaturized junction box. This flexible conduit with strain relief features provides accessible wiring pathways while allowing the junction box to maintain its compact size for installation through small openings.
2Reliability
If the junction box is securely fastened to the lamp housing, then electrical connections are stable, but installation and removal become difficult due to tight joist spacing
Solution Approach 1:
The connection system transitions from rigid to dynamic through the flexible conduit that can bend and flex. This allows the junction box to be securely attached while enabling easy installation and removal by simply disconnecting the flexible conduit, overcoming the constraints of tight joist spacing.
Solution Approach 2:
The flexible conduit with strain relief features provides a flexible connection between the lamp housing and junction box. This flexible connection maintains secure electrical connections while allowing easy installation and removal, resolving the contradiction between connection stability and operational ease.
3Ease of manufacture
If the lighting fixture is supported only by an existing ceiling through a small opening, then installation is simpler, but the junction box and components must be miniaturized making wiring challenging
Solution Approach 1:
The flexible conduit provides an additional dimensional pathway for wiring that extends from the small ceiling opening to the miniaturized junction box. This allows wiring access in three-dimensional space rather than being constrained to the limited two-dimensional space of the small opening, simplifying installation despite miniaturization.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates easier installation and removal of lighting fixtures by providing accessible and secure connections, reducing labor and material requirements while ensuring secure electrical connections and strain relief.
Implementation Method 1
resiliently biased stop
Data Source
AI summary
A recessed lighting fixture includes a lamp housing and a separate compact junction box, which contains a power supply that drives the lamp and serves in part to divide the interior cavity of the junction box into two separate wiring compartments. The junction box has two end walls spaced along an axis and a releasably secured. The lighting fixture is particularly suitable for retrofit installations, especially where small aperture downlights are desired.