Flush-Mounted Box With Sliding Bracket For Wiring Access

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Standard metal housing designs for light fittings in ceilings have limited access for wiring changes and obstructed visual inspection of transformers or controllers, making repairs difficult and non-intuitive due to obstructive junction boxes.

Innovation Solution

A flush-mounted box system with a longitudinal rail and sliding mounting bracket allows connections to be made outside the box, enabling easy visual inspection and repair while complying with UL1598 and NFPA 70/National Electrical Code standards, and a kit for forming such boxes that reduces transport volume.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a junction box is provided on the outside of the metal housing to facilitate visual inspection and repair, then accessibility for inspection and repair is improved, but the junction box obstructs the view on the transformer or controller when opened

Engineering Contradiction:

Improveaccessibility for inspection and repairVSAvoidvisual inspection of transformer or controller

Core Design Contradiction:

Ease of operationVSDifficulty of detecting and measuring

Solution Approach 1:

The invention divides the housing structure into separate functional zones: a first opening for the light fitting and a second opening for the junction box. This segmentation allows the junction box to be accessed independently without obstructing the view into the main housing cavity where the transformer or controller is located, resolving the contradiction between accessibility and visual inspection capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a mirror or reflective surface positioned within the housing to provide indirect visual access to the transformer or controller when the junction box is opened. This intermediary element allows simultaneous access to the junction box and visual inspection of internal components, eliminating the obstruction problem.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Difficulty of detecting and measuring

If the opening for the light fitting is made large enough to facilitate visual inspection of wiring connections, then inspection capability is improved, but the housing volume available for light fitting installation is reduced

Engineering Contradiction:

Improvevisual inspection of wiring connectionsVSAvoidhousing volume for light fitting installation

Core Design Contradiction:

Difficulty of detecting and measuringVSVolume of moving object

Solution Approach 1:

The invention separates the inspection function into two distinct openings: the first opening (for light fitting installation) and the second opening (for wiring inspection). This allows the second opening to be optimized for visual inspection of connections without compromising the volume available in the main housing for the light fitting, as the inspection function is relocated to a dedicated access point.

Inventive Principle:

Principle #1Segmentation

3Ease of repair

If a hinged door junction box is provided above the light fitting opening, then accessibility for repair is improved, but the junction box obstructs the view on the transformer or controller

Engineering Contradiction:

Improveease of carrying out repairsVSAvoidvisual inspection of transformer or controller

Core Design Contradiction:

Ease of repairVSDifficulty of detecting and measuring

Solution Approach 1:

The patent positions the junction box with its own dedicated opening separate from the light fitting opening, allowing the junction box to be accessed for repairs without the need to open a door that would block the view into the main housing cavity. The segmented design enables independent access to wiring components while maintaining clear visual access to the transformer or controller.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11460172B2Metal flush-mounted box for installing a light fitting, kit and using the kit

Publication Date: 2022.10.04 DELTA LIGHT NV

AI summary

A flush-mounted box for installation of a light fitting includes a metal housing that includes a plurality of side walls, at least one side wall defining an opening configured to mount a junction box and/or a cable entry, a bottom wall mountable to the plurality of side walls and defining at least one cutout configured to receive a light fitting, and a top wall mounted to the plurality of side walls opposite the bottom wall. The box further includes a rail rotatably attached to the top wall, wherein the rail is longitudinal and one end of the rail is positioned above the at least one recess, and a mounting bracket configured for sliding attachment according to a longitudinal direction of the mounting bracket in the rail.