Light Fixture Coupler With Angled Screws For Alignment
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Solution Overview
Problem
Existing mechanical assemblies face challenges in securely and easily joining aligned members, particularly in lighting fixtures, where a secure attachment and easy assembly are desired while maintaining alignment.
Innovation Solution
A coupler system comprising T-shaped rails and channels with undercut cross sections and angled screws is used to align and secure frame members, allowing for easy assembly and alignment of modular segments in lighting fixtures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional joining methods are used for frame members, then secure attachment can be achieved, but assembly complexity and alignment difficulty increase
Solution Approach 1:
The frame members are divided into modular segments with standardized coupling interfaces. Each segment includes a frame member with a rail and abutment face, allowing independent assembly through couplers. This segmentation enables secure attachment while simplifying assembly procedures through standardized connections.
Solution Approach 2:
A coupler is introduced as an intermediary component between frame members. The coupler includes a body with a channel that receives rails from opposing frame members, and threaded holes for fasteners. This intermediary device simplifies the joining process while maintaining secure attachment, eliminating the need for complex direct connections.
2Strength
If traditional joining methods are used for frame members, then secure attachment can be achieved, but alignment precision deteriorates
Solution Approach 1:
The coupler serves as a precision alignment intermediary. The channel in the coupler body is configured to receive rails from opposing frame members, providing precise geometric constraints. The threaded holes are positioned to engage with features on the frame members, ensuring accurate alignment in multiple degrees of freedom while maintaining secure attachment.
Solution Approach 2:
The coupling interface uses specific geometric parameters: the channel cross-section is complementary to the rail cross-section, and threaded holes are angled inward toward the center of the body. These parameter specifications ensure precise alignment and secure attachment simultaneously.
3Ease of operation
If simplified coupling structures are used, then assembly ease improves, but attachment security deteriorates
Solution Approach 1:
The coupler is a simplified intermediary device that maintains attachment security. The body with channel and threaded holes provides a straightforward assembly process while the geometric constraints of the channel and the engagement of threaded holes with frame member features ensure secure attachment.
Solution Approach 2:
The coupler design uses specific parameters: the channel cross-section is complementary to the rail cross-section for easy insertion, while the angled threaded holes provide secure fastening. These parameter choices balance assembly ease with attachment security.
4Strength
If multiple fasteners are used to draw abutment faces together, then attachment security improves, but device complexity increases
Solution Approach 1:
The coupler integrates multiple fastening functions into a single intermediary component. The body with channel and threaded holes provides both alignment and secure attachment, eliminating the need for separate alignment fixtures and fastening devices.
Solution Approach 2:
The coupler performs multiple functions: it aligns frame members in multiple degrees of freedom, provides secure attachment through threaded holes, and facilitates easy assembly through its complementary channel design. This multi-functionality reduces overall device complexity despite using multiple fastening elements.
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
The coupler system provides a secure, aligned joint that is easy to assemble, ensuring the abutment faces of frame members are securely drawn together, maintaining alignment in multiple degrees of freedom without relying on screws for weight support.
Implementation Method 1
The channel has a cross section complementary to the cross sections of the first and second rails and is of a size and shape to receive the first and second rails into the channel
Implementation Method 2
The coupler body defines two threaded holes through the back of the coupler body. Each of the two threaded holes is disposed proximate a respective end of the coupler body and angled inward toward a center of the body
Implementation Method 3
when the rails of the two members are inserted into the channel of the body and the screws are advanced into the body, the tips of the screws engage sidewalls of the first and second openings in the first and second rails, drawing the first and second abutment faces together
Data Source
AI summary
A modular lighting assembly includes two modular segments, each having a frame member. A coupler for forming an assembly, and an assembly formed by the coupler. In one example implementation, two members having abutment faces are drawn together using a coupler. Each of the members has a T having a T-shaped cross section, and the coupler has channel with a T-shaped cross section. The channel receives the ends of the rails. Each rail has an opening in its top face. Two screws are threaded into a back of the coupler and angled toward a center of the coupler, such that the ends of the screws engage sidewalls of the openings in the rails. As the screws are advanced into the coupler body, the ends of the screws are drawn together, drawing together the abutment faces of the two members. In other implementations, other rail and channel shapes may be used.