Configurable Mounting Frame with Breakaway Panels
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Solution Overview
Problem
Conventional mounting frames for direct mount luminaires require multiple frames with different light fixture receiving openings to accommodate variously shaped lighting units, leading to increased product stock and labor-intensive replacement processes, and do not allow toolless installation of junction boxes or other electrical components.
Innovation Solution
A configurable mounting frame with a base and breakaway panels that can change the shape of the light fixture receiving opening and a locking feature for toolless attachment of electrical components, enabling the same frame to accommodate different lighting unit shapes and facilitating post-installation coupling of junction boxes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional mounting frames with fixed-shaped light fixture receiving openings are used, then each frame is simple in structure and easy to manufacture, but multiple different frames are required to accommodate variously shaped lighting units, increasing product stock and complexity
Solution Approach 1:
The mounting frame is divided into a base and detachable side wall portions. The side walls can be removed or reconfigured to change the shape of the light fixture receiving opening from circular to rectangular or other shapes, allowing a single base to accommodate multiple lighting unit shapes without requiring entirely different frame designs.
Solution Approach 2:
The mounting frame transitions from a static, fixed-shaped structure to a dynamic, reconfigurable structure. The side walls are designed to be detachable or adjustable, enabling the frame to adapt its configuration based on the shape requirements of different lighting units, thus providing versatility without increasing overall system complexity.
2Ease of operation
If conventional mounting frames require junction boxes to be attached prior to ceiling installation, then the installation process is simplified in terms of components, but it increases labor time and complexity in remodel scenarios
Solution Approach 1:
The mounting frame is designed with pre-integrated attachment features for junction boxes and electrical components that are built into the base structure. This preliminary design allows these components to be easily attached after the frame is installed in the ceiling, eliminating the need for complex pre-assembly or frame replacement in remodel scenarios.
3Reliability
If conventional mounting frames use fasteners requiring tools for junction box attachment, then the connection is secure and reliable, but the installation process becomes labor-intensive and requires additional tools
Solution Approach 1:
The mounting frame incorporates self-contained attachment mechanisms such as snap-fit features, clips, or integrated locking structures that allow junction boxes and electrical components to be securely attached without requiring external fasteners or tools. The frame structure itself provides the means for secure attachment, eliminating the need for separate fastening tools and operations.
Data Source
AI summary
A configurable mounting frame includes a light fixture receiving opening having a first shape. The light fixture receiving opening is configured to receive a light fixture to mount the light fixture to a mounting surface. Further, the configurable mounting frame includes breakaway panels that are detachable to change the shape of the light fixture receiving opening from the first shape to a second shape that is different from the first shape. Furthermore, the configurable mounting frame includes locking features that are configured to toollessly and releasably lock an electrical or electronic component such as a junction box-driver assembly thereto.