Adjustable Hanger Bar Assembly with Bendable Foot

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Solution Overview

Problem

Conventional adjustable hanger bar assemblies for recessed lighting fixtures lack stability and structural integrity when extended to accommodate varying ceiling joist spacings, particularly exceeding 16 inches on-center, due to decreased engagement between slidable bars.

Innovation Solution

The design incorporates a telescoping hanger bar assembly with a bendable arm and pre-stressed relief area, allowing the bar to extend and maintain engagement, and a pivoting foot with a notch for receiving ceiling structures, enabling both slidable and bendable adjustment to accommodate different spacings while maintaining stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If hanger bars are extended to accommodate varying ceiling joist spacings, then adaptability is improved, but stability and structural integrity deteriorate due to decreased engagement between slidable bars

Engineering Contradiction:

Improveadaptability to ceiling joist spacingsVSAvoidstability of hanger bar assembly

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The hanger bar assembly is divided into multiple segments including a first bar, second bar, and bendable arm that can be independently positioned. This segmentation allows each component to engage with ceiling joists at different locations while maintaining overall stability through the coordinated action of the segmented parts.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The hanger bar assembly incorporates dynamic elements including a bendable arm that can flex and a telescoping mechanism that allows adjustment of bar lengths. These dynamic features enable the assembly to adapt to various ceiling joist spacings while maintaining stability through controlled movement and engagement at multiple points.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If hanger bars are extended to maximum length, then adaptability to ceiling spacings is improved, but engagement between slidable bars decreases

Engineering Contradiction:

Improveextension capabilityVSAvoidengagement between slidable bars

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The telescoping mechanism employs a nested structure where one bar is received within another bar. This nesting arrangement allows the hanger bar assembly to extend to maximum length for adaptability to large ceiling spacings while maintaining reliable engagement through the interlocking nested components that remain connected even at full extension.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Adaptability or versatility

If two-piece hanger bar construction is used for adjustability, then adaptability to different lengths is improved, but stability and structural integrity deteriorate

Engineering Contradiction:

Improveadjustable lengthVSAvoidstructural integrity

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The invention merges multiple functional components into a unified hanger bar assembly that includes a first bar, second bar, bendable arm, and telescoping mechanism. This combining of components allows the assembly to achieve both adjustability for different lengths and structural integrity through the integrated design that maintains strength across all adjustment positions.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS7784754B2Adjustable hanger bar assembly with bendable portion

Publication Date: 2010.08.31 SIGNIFY NORTH AMERICA CORP

AI summary

The present invention is an adjustable hanger bar assembly for a light fixture. The assembly maintains structural integrity between first and second bars to support a recessed light fixture while being extended to distances where typical mounting assemblies fail. The hanger bar assembly comprises first and second bars which slidably engage one another. One of the first and second bars comprises a foldable foot which may be extended to increase the length of the hanger bar assembly.