LED Downlight Junction Box Swivel Mechanism for Tight Space Access
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Solution Overview
Problem
Existing LED recessed downlights face challenges in fitting into tight spaces due to size restrictions and low ceiling clearances, and they lack easy repair and maintenance options, particularly for smaller diameter units, which require destructive entry to access internal electronics.
Innovation Solution
A versatile downlight design featuring a swiveling junction box with retractable arms and adjustable LED light engine module, allowing for tilt and pan adjustments from below, and a method for replacing the LED driver through the ceiling hole without damaging the ceiling, using a combination of hinges, flexible lock tabs, and a compact mounting system to accommodate various ceiling thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a larger diameter LED downlight is used, then the light output and visibility are improved, but the fixture cannot fit into tight spaces with low ceiling clearances
Solution Approach 1:
The downlight fixture is divided into separate components: a trim ring that remains in the ceiling and a light engine assembly that can be accessed and replaced independently. This segmentation allows the light engine to be optimized for performance while the trim ring maintains a compact profile suitable for tight spaces.
Solution Approach 2:
The patent implements adjustable positioning mechanisms that allow the light engine to be tilted and positioned at various angles after installation. This dynamic adjustment capability enables the fixture to fit in tight spaces while still providing optimal light output and distribution.
2Volume of moving object
If a smaller diameter LED downlight is used, then the fixture fits into tight spaces, but the internal electronics cannot be accessed for repair without damaging the ceiling
Solution Approach 1:
The fixture is segmented into a permanent trim ring and a removable light engine assembly. The light engine can be independently accessed, removed, and replaced through the ceiling opening without damaging the ceiling itself, enabling easy maintenance of compact fixtures.
Solution Approach 2:
The light engine assembly is designed to be extractable from the ceiling through the trim ring opening. This extraction capability allows technicians to access internal electronics for repair or replacement without cutting into or damaging the ceiling structure.
3Adaptability or versatility
If a separate fixture is designed for each installation type (new construction vs. retrofit), then each fixture is optimized for its specific application, but inventory complexity and the number of SKUs increase
Solution Approach 1:
The trim ring is designed as a universal component that can be used for both new construction and retrofit installations. The same trim ring accommodates different light engine assemblies, reducing inventory complexity while maintaining optimization for various installation types.
Solution Approach 2:
The mounting system includes adjustable elements that can adapt to different ceiling conditions and installation types. This dynamic adaptability allows a single fixture design to serve multiple installation scenarios, reducing the need for multiple specialized SKUs.
Data Source
AI summary
The present invention may be directed to an improved LED downlight with enhanced features including a multi-adjustable junction box and cover assembly, and arm and hinge mechanisms for better installation and packaging of said improved LED downlight. The versatile configuration of the junction box, mounting plate arm, and hinge mechanisms may allow the entire assembly to be maneuvered over various sized ceiling holes for ease of driver and LED replacement and maintenance. Other features and improvements may include compact compressible and expandable three-piece hangar bar mounting brackets, an integral air-tight box, and/or a system for mounting the improved LED downlight to various ceiling thicknesses. The improved LED downlight may be used in both new construction and remodel retrofit installations, sharing the majority of parts, providing ease and flexibility for the installer.