Lighting Junction Box Assembly With Leg-Spring Ceiling Mounting
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Solution Overview
Problem
Existing lighting junction boxes are limited in their ability to be installed directly to an existing ceiling without supporting structures, and they lack effective means for temporary support during installation, which complicates the remodeling process.
Innovation Solution
A lighting-junction-box-assembly that includes a lighting junction box with leg-springs for temporary support and mounting tabs for secure attachment to the ceiling, allowing for installation in areas without nearby supporting structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing lighting junction boxes are used, then they can be installed close to supporting structures like ceiling joists, but they cannot be installed directly to the ceiling in areas without nearby supporting structures
Solution Approach 1:
The junction box is divided into a main body and a separate mounting bracket assembly. The mounting bracket can be attached to the ceiling independently and then the junction box is secured to the bracket, allowing installation in locations without structural support nearby while keeping the main junction box design simple and standard.
Solution Approach 2:
A mounting bracket serves as an intermediary element between the ceiling and the junction box. This bracket can be anchored to the ceiling using various methods (screws, adhesives, mechanical anchors) and provides a mounting surface for the junction box, enabling installation in previously inaccessible locations.
2Ease of operation
If traditional mounting methods are used, then secure attachment is achieved, but temporary support during installation is not provided
Solution Approach 1:
The mounting bracket is installed and secured to the ceiling before the junction box is attached. This preliminary action provides a stable foundation and allows the installer to work comfortably without needing to support the junction box during wiring and connection operations.
Solution Approach 2:
The mounting system transitions from a temporary state (bracket installation) to a permanent state (junction box secured to bracket). The design allows for easy adjustment and positioning during installation, then provides rigid, stable support once assembled.
3Device complexity
If all circuitry is housed within the lighting junction box, then a single box is sufficient, but heat dissipation is compromised
Solution Approach 1:
The electrical system is segmented into two separate junction boxes. The first junction box contains the primary circuitry and wiring connections, while the second junction box houses additional circuitry that generates heat. This segmentation allows each box to be sized and positioned for optimal heat dissipation while maintaining structural simplicity.
Solution Approach 2:
The second junction box acts as a separate thermal management unit, isolating heat-generating circuitry from the primary lighting junction box. This intermediary structure allows heat to dissipate independently without affecting the temperature-sensitive components in the first junction box.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the secure and flexible installation of lighting junction boxes in existing ceilings, improving ease of use during remodeling and providing better heat dissipation through the use of a separate junction box for circuitry.
Implementation Method 1
leg-springs which are configured to at least temporarily hold up the lighting junction box within a newly formed ceiling cutout
Data Source
AI summary
A lighting-junction-box-assembly-for-remodel (assembly) has a lighting-junction-box, leg-springs attached to the lighting-junction-box, and mounting-tabs attached to the lighting-junction-box. The leg-springs are used to (temporarily) hold (by friction) the assembly within a hole in an existing ceiling, sized to fit the assembly. While the leg-springs are (temporarily) holding the assembly within the hole in the existing ceiling, other/different holes within extension-portions of the mounting-tabs are used to secure the entire assembly to the existing ceiling, via mechanical fasteners passing through the extension-portion holes and into the existing ceiling. An existing ceiling may be retrofitted with this assembly to have a lighting-junction-box where desired/needed in that existing ceiling; and as such, this assembly is particularly useful in remodeling situations (applications); however, the assembly may also be used in new construction. The assembly may also include a second junction-box to offload some of the circuitry that would otherwise be included within a lighting can.