Recessed Lighting Outer Casing with Integrated Junction Box
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Solution Overview
Problem
Traditional recessed lighting fixtures are bulky and expensive due to the need for a separate junction box and horizontally oriented frame, which limits adjustability and compliance with building codes.
Innovation Solution
A compact outer casing design that houses a unified light source module and driver, directly attached to hangar bars without a horizontal frame, allowing for vertical and horizontal adjustment and compliance with safety codes, using a unified casting and trim to create a seamless integration with ceilings or walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a separate junction box and horizontally oriented frame are used, then structural stability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the junction box, horizontal frame, and can into a single integrated outer casing structure. The outer casing directly attaches to hangar bars and houses both the junction box and light source module, eliminating the need for separate structural components while maintaining structural stability through the unified design.
Solution Approach 2:
The outer casing serves multiple functions simultaneously: it acts as the structural frame, houses the junction box for electrical connections, and provides mounting for the light source module. This multi-functional design replaces traditional separate components, reducing device complexity while maintaining stability.
2Stability of the object's composition
If a separate junction box and horizontal frame are used, then structural stability is improved, but manufacturing cost increases
Solution Approach 1:
By merging the junction box, frame, and can into a single outer casing, the patent reduces the number of parts that need to be manufactured, assembled, and inventoried. This integration simplifies the manufacturing process and reduces costs while the unified structure maintains structural stability.
3Stability of the object's composition
If can and junction box are attached to horizontal platform, then structural stability is improved, but adjustability is lost
Solution Approach 1:
The outer casing incorporates adjustable mounting mechanisms that allow vertical and horizontal repositioning on the hangar bars. The can and light source module are mounted to the outer casing in a way that permits adjustment, enabling the fixture to adapt to different installation requirements while the outer casing itself maintains structural stability.
4Stability of the object's composition
If traditional components are used, then structural stability is improved, but fixture size increases
Solution Approach 1:
The patent nests the junction box and light source module within the outer casing structure, similar to nested dolls. The junction box is positioned inside or integrated with the outer casing, and the light source module is mounted within the same structure, creating a compact, space-efficient design that maintains structural stability through proper structural support.
Data Source
AI summary
An outer casing for a lighting module comprises a closed base end and a sidewall joined to the closed base end. The sidewall and the closed base end together defining a cavity to contain at least the lighting module. The sidewall comprises: a portion having a substantially cylindrical shape; a lower edge, joined to the portion having the substantially cylindrical shape and located opposite to the closed base end, defining a circular opening; two diametrically opposed flat portions, joined to the portion having the substantially cylindrical shape, starting at and extending from the closed base end; and two sloped portions, each sloped portion of the two sloped portions joining a corresponding flat portion of the two diametrically opposed flat portions to the portion of the sidewall having the substantially cylindrical shape. At least one knockout is disposed on at least one flat portion and on the closed base end.