Recessed Luminaire Mounting Bracket Junction Box Integration
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Solution Overview
Problem
The installation of recessed lighting fixtures is complex, requiring significant skill, time, and planning, and poses environmental and safety hazards due to exposure of ceiling areas, which often contain asbestos and dust, and involves separate connections to junction boxes above the ceiling, necessitating licensed electricians for safety reasons.
Innovation Solution
A lighting assembly comprising a mounting bracket with an axial portion and a trim flange ring that allows the light fixture to be securely attached directly to a junction box, with the light fixture disposed inside the junction box, simplifying installation and reducing material requirements while maintaining aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If recessed lighting fixtures are mounted using traditional methods requiring separate ceiling access and mounting hardware, then the light fixtures can be installed, but the installation process becomes complex and time-consuming requiring significant skill and planning
Solution Approach 1:
The patent combines the junction box and mounting bracket into a single integrated unit. The mounting bracket is attached directly to the junction box, eliminating the need for separate ceiling access and multiple mounting components. This merging of functions allows the light fixture to be installed directly at the junction box location without requiring separate ceiling holes or additional mounting hardware, thereby simplifying the installation process while maintaining structural integrity.
2Productivity
If traditional recessed lighting installation methods are used requiring separate ceiling holes and mounting hardware, then light fixtures can be installed, but installation time and labor costs increase significantly
Solution Approach 1:
The mounting bracket is pre-attached to the junction box before the light fixture is installed. This preliminary action eliminates the need for on-site ceiling work, hole drilling, and separate mounting operations. The pre-assembled bracket-junction box unit is simply positioned and secured, dramatically reducing installation time and labor requirements while maintaining secure fixture attachment.
3Reliability
If traditional installation methods exposing ceiling areas are used, then light fixtures can be installed, but exposure to hazardous materials such as asbestos and dust increases safety risks
Solution Approach 1:
The invention extracts the mounting function from the ceiling structure and relocates it to the junction box. By attaching the mounting bracket directly to the junction box and installing the light fixture at the junction box location, the method eliminates the need to disturb ceiling materials. This extraction of the mounting operation from the ceiling environment removes workers from exposure to hazardous materials such as asbestos and dust while maintaining secure fixture installation.
4Ease of manufacture
If separate ceiling access is required for mounting light fixtures, then traditional installation can proceed, but the number of materials and components required increases
Solution Approach 1:
The junction box serves multiple functions: it provides electrical connections and simultaneously serves as the mounting structure for the light fixture. The mounting bracket attached to the junction box eliminates the need for separate ceiling access holes, traditional mounting hardware, and additional structural components. This multi-functionality reduces the total number of parts and materials required while maintaining installation integrity.
Data Source
AI summary
A lighting assembly for illuminating an architectural space includes a mounting bracket with an axial portion, a trim flange ring including an outer surface, and a light fixture including a flange with an external surface such that the lighting assembly has an installed configuration. The axial portion includes an annular cross-section and at least one open end. In the installed configuration, at least a portion of the light fixture is disposed inside the axial portion. In the installed configuration, the trim flange ring is disposed between the mounting bracket and the light fixture. In the installed configuration, the outer surface faces the architectural space such that the outer surface is a concentric ring around the external surface of the flange of the light fixture.