Interlocking Frame Coupling for Low-Sag Optical Fixture Grids

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Solution Overview

Problem

Existing mounting systems for optical fixtures in lattice arrangements face challenges such as high load-bearing stress, time-consuming installation, and difficulty in visually verifying secure interlocking of components, leading to potential sag and misalignment of fixtures.

Innovation Solution

A coupling system comprising a frame with circumferentially arranged mounts and a coupling device that engages with mounts on adjacent frames, allowing for interlocking to form various configurations like rows, columns, or grids, while providing indicators to ensure secure locking and reducing load-bearing stress through balanced horizontal and vertical coupling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If fixtures are mounted in columns and rows in a lattice arrangement, then fixtures can be supported and arranged in organized configurations, but high load-bearing stress is placed on the structural framework

Engineering Contradiction:

Improvefixture arrangement stabilityVSAvoidload-bearing stress

Core Design Contradiction:

Stability of the object's compositionVSStress or pressure

Solution Approach 1:

The coupling device is divided into multiple coupling elements (first coupling element, second coupling element, third coupling element, fourth coupling element) that distribute the load-bearing stress across different attachment points on the structural framework. Each coupling element independently supports fixtures at different locations, segmenting the overall load path and reducing concentrated stress on any single structural component.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The coupling device extends in multiple spatial dimensions with coupling elements arranged both horizontally and vertically. This multi-dimensional arrangement allows the device to span across the structural framework in various directions, distributing loads across both horizontal and vertical structural members, thereby reducing the burden on any single dimension of the framework.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of manufacture

If traditional mounting methods are used, then fixtures can be installed, but the installation process is time consuming

Engineering Contradiction:

Improveinstallation easeVSAvoidinstallation time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The coupling device is provided as a pre-assembled unit with multiple coupling elements already integrated into a single structure. This segmentation allows the entire multi-point attachment system to be installed as one component rather than assembling multiple separate fasteners, significantly reducing installation time while maintaining ease of installation through simple attachment to the structural framework.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple coupling elements that would traditionally require separate installation steps are merged into a single integrated coupling device. This combination allows all coupling elements to be attached to the structural framework simultaneously in one installation operation, eliminating the sequential time required for installing each fastener individually while preserving the simplicity of the attachment process.

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If interlocking components are used to secure frames, then structural stability is improved, but it becomes difficult to visually verify whether components are securely interlocked

Engineering Contradiction:

Improveinterlocking strengthVSAvoidvisual verification difficulty

Core Design Contradiction:

StrengthVSDifficulty of detecting and measuring

Solution Approach 1:

The coupling device includes visual indicators that change color or display different visual states to indicate whether the coupling elements are properly engaged with the structural framework. When the interlocking components are securely attached, the indicators display a first visual state (such as a green color or visible alignment feature), and when not properly engaged, they display a different visual state, enabling immediate visual verification of secure interlocking without requiring inspection of the hidden mechanical connections.

Inventive Principle:

Principle #32Color changes

4Quantity of substance

If columns or rows are made taller or wider to accommodate more fixtures, then fixture capacity increases, but sag develops resulting in fixtures being out of line

Engineering Contradiction:

Improvefixture capacityVSAvoidfixture alignment precision

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The coupling device divides the support function into multiple discrete coupling elements distributed across the structural framework. Each coupling element independently maintains the position of attached fixtures, preventing cumulative sag effects that would occur in continuous long-span structures. This segmentation allows the system to support larger quantities of fixtures across taller or wider arrangements while each individual coupling point maintains precise alignment, preventing overall misalignment of the fixture array.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20250172276A1Systems for a coupling system

Publication Date: 2025.05.29 MARTIN PROFESSIONAL

AI summary

Systems are provided a coupling system. In one example, the coupling system includes a frame including a plurality of mounts circumferentially arranged along a ring of the frame, and a coupling device engaged with a first mount of the plurality of mounts and a second mount of a second frame. The plurality of mounts and the second mount include rails complementary to recesses of the coupling device.