Adjustable Recessed Lighting Junction Box With Telescoping Hanger Bars
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Solution Overview
Problem
Traditional recessed lighting systems are bulky and require separate mounting of the junction box and can for the driver and light source module, making adjustment and installation cumbersome and costly.
Innovation Solution
A compact recessed lighting system with a unified casting that houses both the light source module and driver in a shared junction box, allowing for adjustable positioning along hangar bars and compliance with building codes, using a monolithic unified casting with fins for heat dissipation and a twist-and-lock mechanism for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional recessed lighting systems use separate mounting of junction box and can for driver and light source module, then the system provides functional separation and ease of assembly, but the system becomes bulky and installation becomes cumbersome and costly
Solution Approach 1:
The patent combines the junction box and can into a single integrated housing structure that accommodates both the driver and light source module. This merging eliminates the need for separate mounting of multiple components, reducing installation complexity and overall system bulk while maintaining all necessary functional separations internally.
Solution Approach 2:
The integrated housing serves multiple functions simultaneously: it acts as the junction box for electrical connections, the can for mounting and structural support, and the enclosure for housing both the driver and light source module. This multi-functionality reduces the number of separate components needed, thereby reducing installation complexity and material usage.
2Ease of manufacture
If traditional recessed lighting systems use separate mounting components, then each component can be optimized independently, but the overall system requires more materials and becomes more costly
Solution Approach 1:
By merging the junction box and can into a single integrated housing, the patent reduces the total quantity of materials required. Instead of manufacturing and assembling multiple separate metal components, the integrated design uses a single housing structure, thereby reducing material usage and manufacturing costs while maintaining structural integrity and functionality.
3Volume of moving object
If the lighting system uses a compact unified design, then installation space is reduced and serviceability is improved, but the system must comply with building codes for heat dissipation and electrical safety
Solution Approach 1:
The integrated housing incorporates localized heat dissipation features such as fins or vents in specific areas where thermal management is critical. This local quality approach ensures that building code requirements for heat dissipation are met within the compact design, maintaining reliability and code compliance without requiring additional space.
Solution Approach 2:
The driver and light source module are nested within the integrated housing in a space-efficient arrangement. This nesting allows the system to meet compact installation space requirements while maintaining proper separation and thermal management zones within the housing, ensuring compliance with electrical safety and heat dissipation codes.
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 system reduces bulk and installation complexity, lowers costs by minimizing material usage, and ensures compliance with safety regulations through a compact, adjustable design that simplifies serviceability.
Implementation Method 1
a monolithic unified casting with fins for heat dissipation
Implementation Method 2
a monolithic unified casting with fins for heat dissipation
Data Source
AI summary
A junction box having a cavity to contain electrical wires that provide a connection to a building mains voltage from an electrical system of a building is coupled to a plurality of telescoping hanger bars to hold the junction box in a wall or ceiling in the building. Each telescoping hanger bar is extendible and/or retractable to vary a length of the hanger bar. A position of the junction box is adjustable along the length of each telescoping hanger bar. In one example, the apparatus does not include a can, separate from the junction box, to contain a lighting device of a recessed lighting assembly.