Configurable Flat Mounting Frame for Adjustable Luminaire Openings
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Solution Overview
Problem
Conventional mounting frames require multiple frames with differently shaped light fixture receiving openings to accommodate various lighting units, leading to increased product stock keeping units and labor-intensive frame replacements during remodels, and lack flexibility in hanger bar dimensions and positioning.
Innovation Solution
A configurable flat mounting frame with breakaway panels and adjustable hanger bars that allow for customizable light fixture receiving openings and hanger bar attachments, enabling a single frame to fit various lighting units and ceiling applications.
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 design and easy to manufacture, but multiple different frames are required to accommodate various lighting unit shapes and sizes, increasing product SKUs and inventory complexity
Solution Approach 1:
The mounting frame incorporates detachable hanger bars that can be separated and reconfigured. The frame is divided into modular components including the main frame body and interchangeable hanger bar assemblies, allowing different configurations for different lighting unit requirements without needing entirely different frame designs
Solution Approach 2:
The mounting frame transitions from a fixed, static design to a dynamic, adjustable system. Hanger bars can be detached, repositioned, and reattached at different positions on the frame, enabling the same frame to adapt to various ceiling joist spacings and lighting unit configurations through on-site adjustments rather than requiring multiple pre-designed frame variants
2Ease of manufacture
If multiple different mounting frames are produced for different lighting unit shapes, then each frame can be optimized for its specific application, but manufacturing complexity and inventory management become more difficult
Solution Approach 1:
A single mounting frame design serves multiple functions by accommodating different lighting unit shapes and sizes through adjustable hanger bar configurations. The universal frame design with standardized attachment points and detachable hanger bars eliminates the need to produce multiple specialized frame variants while maintaining the ability to support diverse lighting applications
Solution Approach 2:
The mounting frame allows adjustment of key parameters such as hanger bar length, position, and orientation to accommodate different lighting unit requirements. By changing these parameters on-site rather than producing different frame designs, the system maintains manufacturing simplicity while achieving versatility across multiple applications
3Adaptability or versatility
If fixed-length hanger bars are used in mounting frames, then the frame structure is simple and stable, but the frame cannot accommodate different ceiling joist spacings, requiring custom frames for different installations
Solution Approach 1:
The hanger bar system transitions from fixed-length to adjustable-length configurations. Hanger bars can be detached and replaced with different lengths, or repositioned along the frame at different attachment points, allowing the system to adapt dynamically to various ceiling joist spacings without requiring custom-designed frames for each installation scenario
Data Source
AI summary
A flat mounting frame for direct mount luminaires is disclosed that has a set of features that allows for different hanger bar attachments and length adjustments. The flat mounting frame has multiple sets of features incorporated that permit the end user to adjust its overall length, the size of the luminaire opening, and the locations of attached hanger bars.