Recessed Light Fixture Mount for Smooth Tilt and Small-Opening Install
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Solution Overview
Problem
Existing adjustable light fixtures, particularly recessed ones, suffer from issues such as binding, undesirable movements, complex mechanisms, large installation requirements, and limited access to components, as well as compromised light quality and aesthetics due to removable lenses.
Innovation Solution
The fixtures incorporate a mechanical actuator with arcuate bearing surfaces to minimize binding and undesirable movements, a smooth rotating interface, and a mount design allowing installation through small openings, along with a removable shroud assembly that maintains light quality by avoiding features in the light path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a mechanical actuator with arcuate bearing surfaces is used to enable tilting adjustment, then the light source can be adjusted in direction, but the mechanism becomes more complex and larger
Solution Approach 1:
The mechanical actuator is divided into separate functional components: a tilting mechanism with arcuate bearing surfaces for directional adjustment, and a swiveling mechanism with gear teeth for rotational adjustment. This segmentation allows each component to perform its specific function efficiently while reducing overall complexity by isolating adjustment movements.
Solution Approach 2:
The light source assembly is designed to be dynamically adjustable through multiple degrees of freedom - it can tilt relative to the housing, swivel independently, and rotate. This dynamic capability allows the light direction to be precisely controlled for different installation orientations without requiring a completely different mechanical structure for each adjustment type.
2Ease of operation
If a tilting mechanism is used to adjust light direction, then light output can be controlled, but the mechanism is prone to binding and falling out of adjustment
Solution Approach 1:
The mechanism incorporates latching features that provide tactile feedback and mechanical retention at adjusted positions. The gear teeth with corresponding recesses create positive engagement that prevents the light source from accidentally shifting or falling out of its adjusted orientation, ensuring long-term reliability.
Solution Approach 2:
The arcuate bearing surfaces provide a curved contact interface between the tilting mechanism components. This curved geometry distributes contact forces more evenly, reducing binding and friction while allowing smooth adjustment movement. The curved surface also naturally guides the adjustment motion along a controlled path.
3Ease of operation
If a swiveling mechanism with meshing gears is used, then the light source can be rotated, but the adjustment feels jerky and requires considerable effort
Solution Approach 1:
The swiveling mechanism replaces traditional meshing gear teeth with a cam and follower system. The cam profile is designed to convert rotational motion into controlled swiveling movement of the light source, eliminating the jerky engagement characteristic of meshing gears. This substitution maintains the rotational adjustment capability while providing smooth, low-effort operation.
4Reliability
If a mount requiring access to both sides of a structure is used, then the fixture can be securely mounted, but installation becomes more difficult and time-consuming
Solution Approach 1:
The mounting system is segmented into a mounting bracket component and a fixture housing component. The bracket can be attached to one side of the structure (ceiling, wall, or floor), while the housing is then positioned and secured from the other side. This segmentation allows secure mounting without requiring simultaneous access to both sides during installation.
Solution Approach 2:
A mounting bracket serves as an intermediary component between the structure and the fixture housing. The bracket provides attachment points on one side of the structure, and the housing connects to the bracket from the opposite side. This intermediary element enables secure mounting while simplifying the installation process by eliminating the need for direct through-structure mounting.
5Ease of operation
If a removable lens with tabs or recesses is used, then the lens can be easily removed, but light quality is compromised and aesthetics are affected
Solution Approach 1:
The lens retention features (tabs or recesses) are extracted from the light path area and repositioned to the periphery of the lens assembly. This allows the lens to be removed through alternative access points that do not interfere with the light output, maintaining optimal light quality and aesthetics while preserving ease of maintenance access.
Data Source
AI summary
Some embodiments of the present fixtures include a mechanical actuator configured to direct movement of a light mount along an arcuate path defined by arcuate bearing surface(s). Some embodiments of the present fixtures include a rotatable portion coupled to a stationary portion at an interface that is at least partially defined by smooth surface(s). Some embodiments of the present mounts include a base having a sidewall that defines an outer perimeter and mounting tab(s), each movable between a deployed state and a retracted state in which at least a portion of the mounting tab is disposed within the outer perimeter. Some embodiments of the present removable shroud assemblies include a lens coupled to a second end of a shroud and movable from a first position to a second position in which a portion of the lens is not in contact with the second end of the shroud.