Lighting Fixture Tenon Cradle Structural Integrity

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Solution Overview

Problem

Outdoor lighting fixtures face challenges in balancing lightweight construction with the need for structural integrity to withstand environmental forces and installation abuses, particularly with composite materials that are prone to damage from over-tightening during installation.

Innovation Solution

The design incorporates a tenon cradle with multiple ribs and a stepped structure within the housing, featuring a clamp assembly with elongated nuts and a cradle bracket that includes preferential bending regions to distribute forces and prevent damage, along with an axial channel for improved alignment and load distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If composite materials are used to reduce weight, then the lighting fixture becomes lighter and easier to install, but the structural integrity decreases and the housing becomes prone to damage from over-tightening during installation

Engineering Contradiction:

Improvefixture weightVSAvoidhousing strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The housing is segmented into multiple rib structures (axial ribs, circumferential ribs, diagonal ribs) that divide the load paths and distribute installation forces across multiple discrete structural elements, preventing stress concentration that would damage composite materials while maintaining overall housing strength

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs composite materials with embedded reinforcement elements (metal ribs, strengthening members) within the composite housing structure, combining the weight advantages of composites with the strength of metal reinforcements to resolve the contradiction between lightweight construction and structural integrity

Inventive Principle:

Principle #40Composite materials

2Strength

If metal housings are used to ensure structural integrity, then the housing can withstand installation abuses and environmental forces, but the weight increases making installation more difficult and requiring additional safety equipment

Engineering Contradiction:

Improvehousing strengthVSAvoidfixture weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

Instead of using metal throughout the entire housing, the patent applies metal reinforcement elements only in specific locations where structural strength is needed (at rib intersections, bolt boss areas, and load-bearing regions), maintaining lightweight composite construction in non-critical areas while providing localized metal strength where required

Inventive Principle:

Principle #3Local quality

3Reliability

If traditional clamping mechanisms with bolts are used to attach the fixture to the pole, then the fixture can be securely mounted, but over-tightening during installation may break, fracture, crack, or damage the composite housing

Engineering Contradiction:

Improvemounting reliabilityVSAvoidinstallation damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent incorporates cushioning and stress-distributing structural features (flexible rib designs, reinforced mounting zones, compliant mounting interfaces) that are built into the housing before installation, which absorb and distribute the harmful forces from over-tightening during the installation process, preventing damage before it occurs

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent introduces intermediary structural elements (mounting brackets, reinforcement plates, distributed fastening systems) between the clamping mechanism and the composite housing that mediate the connection, allowing secure mounting while protecting the composite housing from direct exposure to damaging installation forces

Inventive Principle:

Principle #24Intermediary (Mediator)

4Ease of operation

If the housing is designed to be lightweight for easier installation, then fewer installers are needed and installation is safer, but the housing may not withstand extreme environmental conditions and installation abuses

Engineering Contradiction:

Improveinstallation easeVSAvoidenvironmental resistance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent uses composite materials with strategically placed reinforcement elements that provide high strength-to-weight ratio, enabling the housing to be lightweight enough for single-installer handling while simultaneously withstanding extreme environmental conditions and installation abuses through the reinforced composite structure

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11635191B2Lighting fixture with high structural integrity

Publication Date: 2023.04.25 LED-IP MANAGEMENT LLC

AI summary

Tenon-mounted lighting fixtures with high structural integrity are provided. In one embodiment, the lighting fixture has a housing that has an integrally formed tenon cradle, which is configured to receive a tenon of a light pole. A light source is also mounted on a bottom side of the housing. The tenon cradle is between a first bolt boss and a second bolt boss, and is in communication with a rear opening of the housing. The first and second bolt bosses may be integrally formed in the housing. The tenon cradle includes multiple ribs. An arcuate cross rib resides in a first plane in which a first bolt shaft of the first bolt boss and a second bolt shaft of the second bolt boss reside. An axial rib intersects the arcuate cross rib and runs perpendicular to the first plane.