Deployable Tab Mounting Bracket for Hat Channel Luminaire Installation
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Solution Overview
Problem
Current luminaire mounting systems require multiple tools and additional hardware to attach light fixtures to furring/hat channel grids, making the installation process time-consuming and difficult, especially when working at elevated heights, and often necessitate vertical adjustments to align with ceiling materials.
Innovation Solution
A mounting bracket with deployable tabs that engage hat channels of varying heights, allowing for tool-free or minimally tool-assisted installation by pivoting tabs to secure the luminaire fixture frame without the need for additional hardware, using a living hinge mechanism and slots to adjust the frame's position relative to the ceiling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional mounting systems use multiple tools and additional hardware to attach light fixtures to furring/hat channel grids, then the connection strength and stability are improved, but the installation time and complexity increase
Solution Approach 1:
The mounting bracket integrates multiple functions into a single component: the tab structure provides both the mounting connection and the engagement mechanism with hat channels, eliminating the need for separate screws, clips, or adjustment hardware. The living hinge integrates the deployment mechanism directly into the bracket structure, combining what would traditionally require multiple parts into one unified component.
Solution Approach 2:
The tab structure is designed to be self-deploying through the living hinge mechanism, automatically engaging with hat channels without requiring external tools or additional adjustment hardware. The bracket serves its own deployment and engagement functions through its inherent structural design, eliminating the need for separate installation tools.
2Adaptability or versatility
If traditional mounting systems use additional hardware for vertical adjustment, then the adaptability to different ceiling heights is improved, but the device complexity increases
Solution Approach 1:
The tab structure incorporates a living hinge that enables dynamic deployment between a stowed position and an engaged position. This dynamic mechanism allows the bracket to adapt to different hat channel heights through the tab's ability to pivot and engage at various positions, eliminating the need for fixed adjustment hardware or multiple bracket configurations.
Solution Approach 2:
The single bracket design with deployable tabs serves multiple functions: structural support, vertical adjustment, and engagement with hat channels of varying heights. The living hinge mechanism provides both the deployment function and the adjustment function, making the bracket a universal mounting solution that works across different ceiling configurations without requiring additional specialized hardware.
3Stability of the object's composition
If traditional mounting systems require multiple connection points, then the stability of installation is improved, but the ease of operation deteriorates
Solution Approach 1:
The mounting bracket consolidates multiple connection functions into a single integrated structure. The elongated body with opposing ends provides distributed attachment points while the deployable tabs provide engagement points, all within one component. This merging maintains stability through multiple contact points while simplifying operation to a single deployment action.
Solution Approach 2:
The tab structure automatically engages with hat channels through its own deployment mechanism, eliminating the need for separate fastening operations. The living hinge provides the mechanical advantage needed for the tab to self-lock into position, maintaining stable connection without requiring additional tools or complex fastening procedures.
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
Enables quick, consistent, and stable installation of luminaire fixtures across different hat channel heights without the need for extensive tool usage or additional hardware, simplifying the process and reducing installation time and complexity.
Implementation Method 1
The tabs may be connected to the opposing ends by a hinge, such as a living hinge
Data Source
AI summary
A mounting bracket (20) for a luminaire fixture frame (12) having one or more tabs (30) to engage a hat channel or the like. The one or more tabs (30) are positionable between an un-deployed position and a deployed position to operably engage the hat channel.