Illuminated Sign Mounting Structure with Biasing and Segmentation
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Solution Overview
Problem
Current illuminated signs face challenges in installation complexity, sagging due to weight, and the need for replacing entire units when only internal components fail, leading to inefficiencies and increased costs.
Innovation Solution
A mounting device with a removable sign insert and canopy element that secures to junction boxes, providing ease of installation, hiding screws, and preventing sagging, while allowing for separate replacement of internal components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mounting devices with multiple parts are used, then the sign can be securely mounted to the junction box, but the installation process becomes complicated and time-consuming
Solution Approach 1:
The patent combines multiple mounting components (mounting plate, canopy, and securing mechanisms) into a single integrated mounting device that attaches to the junction box as one unit, eliminating the need for separate installation of multiple parts and reducing installation complexity while maintaining secure mounting
Solution Approach 2:
The mounting device is designed with universal compatibility to fit standard junction boxes while incorporating multiple functions (structural support, electrical access, and sign securing) into a single device, reducing the number of separate components needed
2Strength
If metal sign housing is used, then the sign provides durable structure, but the sign becomes heavy and tends to sag from the ceiling or wall
Solution Approach 1:
The patent introduces asymmetric biasing structures (such as offset mounting points or unequal support elements) that create a mechanical advantage to counteract gravitational force on the heavy metal sign, preventing sagging while maintaining the durable metal construction
Solution Approach 2:
The mounting device incorporates biasing elements that exert counteracting force against the weight of the metal sign housing, preventing it from sagging or pulling away from the ceiling or wall mounting surface
3Reliability
If pipe fitting with lock washer and nut is used to bias sign toward ceiling, then the sign can be secured, but the installation time increases and shadows are cast in the sign
Solution Approach 1:
The patent integrates the biasing function directly into the mounting device structure itself, eliminating the need for separate pipe fittings, lock washers, and nuts, thereby reducing installation time while maintaining the sign's secured position and preventing shadow casting
4Reliability
If entire sign unit is replaced when internal components fail, then the sign functionality is restored, but cost increases and functional components are wasted
Solution Approach 1:
The patent divides the sign into separable modules (sign housing and removable insert containing internal components), allowing the insert to be replaced independently while retaining the functional housing, thereby reducing waste and maintenance costs
Solution Approach 2:
The removable insert design allows functional components (housing, mounting device, canopy) to be recovered and reused when only the internal components fail, reducing material waste and maintenance costs by replacing only the necessary insert rather than the entire sign unit
Data Source
AI summary
There is provided an illuminated sign mounting system and methods for mounting an illuminated sign to a mounting surface.