Concrete Lighting Niche Assembly for Accurate Form-Pour Installation
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Solution Overview
Problem
Existing lighting installations in concrete surfaces face issues with inconsistent illumination due to loosely held light elements, misplacement, and deformation of holding means, and lack of efficient pre-staging during concrete pouring, leading to inefficient and clumsy lighting designs.
Innovation Solution
A system and method using a mounting fixture assembly with a niche sleeve and insert cap that is pre-fitted with electrical wiring, secured to a form board, and embedded in concrete, allowing for stable installation and connection of lighting units after concrete formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If threaded connections are used for holding means to improve gripping, then gripping strength is improved, but deformation of holding means and misplacement occur leading to inconsistent illumination
Solution Approach 1:
The holding means is divided into separate components: a holding element embedded in the concrete formation and a light element with its own holding structure. This segmentation allows each component to be optimized independently - the holding element provides secure anchoring while the light element maintains precise positioning without deformation.
Solution Approach 2:
A holding element acts as an intermediary between the concrete formation and the light element. This intermediate component transfers the gripping function to the concrete while providing a stable interface for the light element, preventing direct deformation of the light element itself.
2Productivity
If light elements are loosely held during concrete pouring, then installation speed is improved, but positioning accuracy deteriorates making proper placement difficult
Solution Approach 1:
The holding element is pre-embedded in the concrete formation before the light element is installed. This preliminary action establishes a stable, pre-positioned anchor point that guides the subsequent placement of the light element, ensuring both speed and precision.
Solution Approach 2:
The holding element is designed to be self-anchoring through its embedding in the concrete formation, eliminating the need for additional fastening operations during light element installation. The concrete itself provides the securing mechanism.
3Ease of operation
If openings in concrete are made larger to accommodate light elements, then ease of installation is improved, but structural integrity and aesthetic appearance deteriorate
Solution Approach 1:
The light element is nested within a niche that is itself embedded in the concrete formation. This nested structure allows the light element to be accommodated within a smaller opening while maintaining structural integrity, as the niche acts as an intermediate container that protects the light element and minimizes concrete disruption.
Data Source
AI summary
An improved system and associated method are disclosed for installing one or more lighting units on levels of a concrete surface during construction. The present system comprises a mounting fixture assembly for positioning a niche member at the surface of the concrete formation, the niche being formed having a tubular chamber open at one end and pre-fitted with electrical wiring at the opposite closed end with additional length of electrical cabling having a proximal end positioned within the chamber of the niche and a remote end routed through the concrete form to connect to an electrical power source. In mounting the niche within the concrete formation, an insert cap formed having a flat top surface with a surrounding flange and an edge wall projecting below is releasably attached to a form board set along the edge of the intended concrete surface and press-fitted along its projecting wall into the open end of the niche chamber to station and stabilize the pre-wired niche during the concrete pouring and formation. Upon completion of the concrete formation, the form board is removed thereby extracting the cap insert from the open end of the niche and leaving the niche in place with its open end and cabling therein accessible for the connection and installation of the selected lighting unit along the concrete surface. A product kit is further disclosed including a light unit for completing an installation