Concealed Luminaire Connection Using Nested Brackets
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Solution Overview
Problem
The assembly of light fixtures into larger arrays or patterns is time-consuming and difficult, especially when multiple fixtures need to be joined, and existing solutions often result in visible fasteners, gaps, or uneven alignments.
Innovation Solution
A connection system comprising inner and outer mating brackets with curved scoop ledges and ramp edges that slide together, creating a concealed and seamless joint, using gravity-assisted nesting and securing members to align and secure the fixtures without visible hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional connection systems are used to join light fixtures, then the fixtures can be connected together, but the assembly process becomes time-consuming and difficult
Solution Approach 1:
The connection system employs nested brackets where an inner bracket is positioned within an outer bracket. The inner bracket attaches to one light fixture while the outer bracket attaches to another fixture, allowing the brackets to nest together and securely join the fixtures. This nested configuration simplifies the assembly process and reduces installation time compared to traditional connection methods.
2Ease of manufacture
If traditional fastening methods are used, then light fixtures can be connected, but visible fasteners and gaps appear at the joints
Solution Approach 1:
The nested bracket design allows the inner bracket to be concealed within the outer bracket, hiding all fasteners and connection hardware from view. This creates a seamless joint appearance between light fixtures without visible gaps or hardware, achieving high aesthetic quality while managing system complexity through the nested configuration.
Solution Approach 2:
The connection system introduces intermediary brackets that serve as mediators between adjacent light fixtures. These brackets are specifically designed to be concealed, acting as hidden intermediaries that join fixtures together while remaining invisible from the exterior, thus eliminating visible fasteners and maintaining aesthetic continuity.
3Productivity
If light fixtures are joined together to form arrays, then larger lighting configurations can be created, but alignment consistency becomes difficult to achieve
Solution Approach 1:
The connection brackets incorporate asymmetric features including locating pins and corresponding recesses that enforce precise alignment between fixtures. The asymmetric geometry ensures that brackets can only be installed in the correct orientation, guaranteeing consistent alignment across multiple joined fixtures and preventing misalignment issues in larger arrays.
Solution Approach 2:
The connection system includes pre-configured alignment features such as locating pins and guide edges that are built into the bracket design before installation. These preliminary alignment mechanisms automatically position fixtures correctly as they are joined, ensuring consistent alignment throughout the array without requiring additional adjustment during installation.
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
This solution significantly reduces assembly time, ensures a seamless and aesthetically pleasing connection with consistent alignment, and accommodates small aperture fixtures while allowing for electrical connections, thereby improving the efficiency and appearance of light fixture installations.
Implementation Method 1
gravity assisted, the inner mating bracket may slide and nest within the outer mating bracket with the curved ramp edge of the inner mating bracket coupling with the curved scoop ledge on the outer mating bracket
Data Source
AI summary
A connection system accommodates small aperture fixtures and provides ample room for electrical connections and a cosmetically superior seam. The connection system may consist of two mating brackets for the concealed joining of segments of light fixtures. The joiner design is completely integral to a fixture, with no externally visible hardware and no additional visual seams. Due to the sweeping nature of the joining action, internal fixture components do not need to be removed in order for correct joining to occur. Additionally this design requires that no components are removed from the fixture prior to joining, significantly reducing the time and effort that goes into joining fixtures in runs.