Concealed Emergency Lighting Retrofit Housing
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Solution Overview
Problem
Existing emergency lighting fixtures require large back boxes for housing components, making it impossible to install them through small wall or ceiling cutouts, and lack self-powered, independent battery backup systems.
Innovation Solution
A concealed emergency lighting system comprising a lamp assembly box and a power source box, connected by a flexible support and armored cable, allowing for installation through a small opening with a U-shaped mounting bracket, enabling all components to be installed independently and self-powered.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a large metal back box is used to house all emergency lighting components, then all components can be housed together, but the back box cannot be installed through a small wall cutout and must be installed before wall covering is attached
Solution Approach 1:
The emergency lighting system is divided into separate modules: a lamp assembly module and a power supply module. Each module has its own housing that can be installed independently through the wall cutout, eliminating the need for a single large back box that requires pre-installation before wall covering.
Solution Approach 2:
The system allows installation through the wall surface (2D cutout) rather than requiring installation within the wall cavity (3D space) before covering. The modular design enables components to be inserted through the opening and positioned on the wall surface, changing the installation dimension from interior cavity to exterior surface.
2Adaptability or versatility
If a remote emergency power source is used for multiple lighting fixtures, then power can be shared across multiple units, but the lighting fixtures do not have independent self-powered battery backup
Solution Approach 1:
The power supply system is segmented into individual battery units integrated with each lighting fixture. Each fixture contains its own battery, charger, and power management circuitry, providing independent backup capability while maintaining the ability to share power architecture across multiple fixtures.
Solution Approach 2:
Each lighting fixture is self-powered with an integrated battery and charging system. The battery can be recharged from the wall outlet through the same opening used for installation, eliminating the need for remote power sources while maintaining independence and reliability of each unit.
3Volume of moving object
If all emergency lighting components are housed in a single back box, then the system is compact, but the housing size prevents installation through small wall or ceiling cutouts
Solution Approach 1:
The compact housing is achieved through segmentation into multiple small modular units rather than one large housing. Each module (lamp assembly and power supply) has a compact size that fits through standard wall cutouts, while the overall system maintains space efficiency through modular integration.
Solution Approach 2:
The modular components are designed to nest within the wall cavity or position against the wall surface, with the lamp assembly and power supply module fitting together in a compact arrangement that minimizes overall system volume while maintaining installability through small openings.
Data Source
AI summary
A concealed emergency lighting system that includes a lamp assembly box and a power source box and a method for installing the emergency lighting system is disclosed. The lamp assembly box has a face plate and a front door pivotably moveable between an open and a closed position and a lamp assembly. The power source box includes a battery and other electrical components that are connected to the lamp assembly. The emergency lighting system can also include a mounting bracket with screws, a flexible support and a flexible armored cable. The method of installing the concealed emergency lighting system includes the steps of: forming an opening in a wall; attaching the mounting bracket to a stud through the opening; connecting the power source; inserting the power source box and the lamp assembly box through the opening; and securing the lamp assembly box to the mounting bracket.